Understanding the Sources and

Remedies of Hydrogen-Assisted Cracking

in Transmission Pipeline Applications
Derick Railling
Product Manager Global Onshore Pipeline
Presentation Outline
Introduction What is hydrogen?
Hydrogen in welding
Poor elongation
Cracking
Sources of hydrogen
Ambient moisture
Residual oils on plate (from machining/cutting)
Lubricants on wire
Raw materials
Filler metals
Filler metal storage
Importance of pre- and post-weld heating
Fisheyes
Summary


What is Hydrogen?
#1 on the periodic table
Lightest element
Most abundant element in the universe
Highly flammable reacts violently with oxygen
to form water

So What?
Hydrogen in Welding
Can squeeze into small spaces in the steel
lattice due to small size.
Very mobile - especially at higher temperatures.
The solubility of hydrogen in iron (or steel) is
much higher in the gamma () phase, which
exists at higher temperatures than in the alpha
phase (). The alpha phase exists at room
temperature.
Sources of Hydrogen
Moisture in the air
Oil, grease, paint, coatings on the base plate
Welding consumables
Lubricant in seam
Raw materials
Moisture in coating (stick electrodes)
Packaging/storage
Shielding gas
Hydrogen Solubility
Hydrogen-Assisted Cracking (HAC)
Also referred to as delayed cracking, cold
cracking, toe cracking, underbead cracking.
When steel cools and transforms from to ,
any hydrogen that is present becomes trapped
in the matrix.
Over time, the hydrogen diffuses and collects as
H
2
gas near defects and grain boundaries in the
matrix.
As the hydrogen gas builds up, the stress levels
increase until cracks form.
HAC compromises the integrity of the weld.
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Video Showing Hydrogen Cracking
http://www.youtube.com/watch?v=bv9ApdzalHM
Requirements for HAC
High strength steel
Crack Sensitive
Microstructure
Inherent to weld metal Stress
Controllable element
for Hobart
Hydrogen
As a producer, we can help reduce HAC via controlling hydrogen in our products.
Reducing the Chances of HAC
Low-hydrogen filler metals
Improving pre- and post-weld heating
Maintaining interpass temperatures
Welding process change
Material handling
Storage methods
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Filler Metals
How to Choose
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Filler Metal Selection
All major processes have an optional hydrogen
designator (GMAW, FCAW, SAW, SMAW).
Filler metal is tested to ANSI/AWS A4.3
(Standard Methods for Determination of the
Diffusible Hydrogen Content).

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What is Diffusible Hydrogen?
Diffusible hydrogen is the monatomic hydrogen that
can diffuse from the weld metal during cooling.
Filler metal is welded on a pre-baked piece of steel (so
that all existing hydrogen is removed).
The welded sample is quenched in an ice bath and
stored in liquid nitrogen or dry ice and alcohol until ready
to test.
The sample is then placed into an analytical apparatus
(canister) to be baked at a given time/temperature.
After the given time/temperature the diffused hydrogen
is measured using a gas chromatography method.
The diffusible hydrogen can also be tested using the
mercury displacement method.
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How to Tell if a Filler Metal is Low
Hydrogen
Look for a hydrogen designator in the AWS
classification, e.g.:
E7018-1 H4R (SMAW)
E70C-6M H4 (Metal-Cored)
E71T-1C H8 (FCAW)
E71T8-Ni1 J H8 (Self-Shielded FCAW)
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What to Use?
Cellulosic SMAW electrodes (XX10)
Commonly used for root pass, fill pass and cap
pass welding.
Good penetration and performance characteristics
(vertical down for pipe welding).
However, these electrodes provide hydrogen levels
far exceeding 16ml/100g (25-60ml/100g).
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Not recommended for steel with a UTS exceeding 60ksi.
Not a good choice for high strength pipe!
Low-hydrogen SMAW electrodes (EXX16 /
EXX18)
Typically used as fill and cap passes.
Hydrogen designations of H4 or H8.
Less penetration than EXX10.
Different performance characteristics (vertical-up
for pipe).
Not acceptable for root pass welding on pipe.

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What to Use?
Hobart metal-cored wires for root pass welding
Typically low levels of hydrogen < 4ml/100g.
Used with Miller RMD (modified short circuit) in the
vertical-down position.
Typically only prone to surface moisture on the
metal powders.
Metal-cored wires are typically prone to surface
moisture on the metal powders, whereas FCAW
products can contain non-metallic raw materials
that may absorb moisture to a greater degree.

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What to Use?
FCAW self-shielded
Typically < 8ml/100g of weld metal.
Special self-shielded products are designed to run
vertical-down on pipe.
FCAW gas-shielded
Typically < 4ml/100g or < 8ml/100g of weld metal.
Like low-hydrogen SMAW (EXX18) these products
are designed for vertical-up welding.

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What to use?
FCAW wires feature a number of hydrogen scavengers like fluoride compounds,
which combine with hydrogen to remove it from the weld!
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Metalloy Metal-Cored Wires Fabshield FCAW-S Cellulosic EXX10
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Diffusible Hydrogen Levels
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If you have an older version of PowerPoint double click icon to play video
Hydrogen Difference 10 Min. After Being in Mineral Oil
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E6010
E71T8-Ni1 J H8 E70C-6M H4
Storage of Filler Metals
All filler metals should be stored in a clean, dry
area and should remain in the original packaging
until ready to be used.
Keep the filler metals sealed.
Minimize or eliminate the transfer of filler metals
from cold to hot environments.
Prevents condensation.
If moved, filler metals should be protected and
allowed time to normalize to ambient temperature.
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Welding Practices to Reduce Hydrogen
Metal-cored, flux-cored and solid wire
Use a longer contact tip-to-work distance (CTWD).
Keep within the recommended range.
Welding outside of the recommended range can lead to:
Loss of shielding gas
Reduced penetration
Poor operability (rough arc, spatter, kick off)
Increased CTWD allows for greater pre-heating of
the wire.


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The Importance of Heat
Pre-heat, Post-Heat and Interpass
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What is Happening?
Heating and rapid cooling during welding.
Puts stresses into the weld.
Creates hard, highly-stressed microstructures that
are more susceptible to HAC.
Rapid cooling = less opportunity for hydrogen to
diffuse out of the weld and heat affected zone
(HAZ).
Rapid cooling = greater opportunity for cracking.
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Pre-Heat, Interpass and Post-Heat
Very critical to maintain the proper pre-heat and
interpass temperature and apply a post-heat
weld treatment (PWHT) when needed.
Produces a softer, less crack-susceptible
microstructure.
Allows hydrogen to diffuse out of the weld metal
and HAZ.
A post-weld soak, PWHT or hydrogen bake-out may
be necessary to further reduce hydrogen trapped in
the weld.
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Traditional Heating Methods
Propane Torches
Hydrocarbon (compound of carbon and hydrogen).
The process of igniting and applying a flame to the
pipe introduces hydrogen into the weld joint.
Does not ensure uniform heating.

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Drives and keeps moisture out of the weld
Reduces the chances of hydrogen-assisted cracking.
Heats Uniformly
Ensures heating consistency.
Improves Safety
Eliminates open flames & exposed heating elements.
Provides faster time-to-temperature
Increases productivity.

Induction Heating (Miller ProHeat 35)
Fisheyes
What They Mean to Pipeline
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Fisheyes
Fisheye: A discontinuity, attributed to the
presence of hydrogen in the weld, observed on
the fracture surface of a weld in steel consisting
of a small pore or inclusion surrounded by an
approximately round, bright area.
(AWS A3.0M/A3.0:2010)
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Fisheye: A discontinuity
An interruption of the typical structures, either
mechanical, metallurgical or in the physical
characteristics.
A discontinuity is NOT necessarily a defect.
Examination/inspection to determine whether
discontinuity can remain or must be removed.
A defect IS a rejectable discontinuity.
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Fisheyes
The center is known as the pupil and the area
around the pupil is the iris.
Fisheyes
Pupil Iris
The pupil is the only original imperfection
associated with the fisheye.
The iris has fractured due to local hydrogen
embrittlement.
Hydrogen collects in pores or near inclusions.
When a slow strain rate is applied fisheyes
may occur (example: nick-breaks or tensile
pulls).


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Fisheyes
Fisheyes have no effect on mechanical
properties (tensile and yield strength, or impact
toughness).
However, they do affect elongation and
reduction of area.
Fisheyes are artifacts of testing a steel that
contains hydrogen and not defects in and of
themselves.
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Fisheyes
API 1104 (Section 5.6.3.3) states Fisheyes, as defined in
AWS A3.0, are not cause for rejection.
Things to Focus On
Proper handling of the pipe
Watching for outside sources of hydrogen
Filler metals
Selecting a low-hydrogen filler metal when welding
higher strength pipe.
Pre-heat, interpass, post-heat

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Summary
Focusing on low hydrogen welding practices
should be a priority to ensure a high integrity
weld.
All factors must be considered and only
changing one variable is not sufficient.
Changing to a low hydrogen filler metal does not
guarantee a reduction in HAC, however, it
greatly reduces the risks.
Proper heating methods must become an
integral part of the welding procedure.
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Questions?
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