Jyoti Prakash et. al.

/ International Journal of Engineering Science and Technology

Vol. 2(5), 2010, 1211-1220

MINIMISING HIC/HAC IN STEEL

USING LOW HYDROGEN ELECTRODE
FOR SMAW
(1) JYOTI PRAKASH
Senior Research Fellow, Mechanical Engineering Dept.
Institute Of Technology, Banaras Hindu University
Varanasi-221005, India
(2) S.P. TEWARI
Associate Professor, Mechanical Engineering Dept.,
Institute Of Technology, Banaras Hindu University
Varanasi-221005, India
(3)BIPIN KUMAR SRIVASTAVA
Senior Research Fellow, Mechanical Engineering Dept.,
Institute Of Technology, Banaras Hindu University
Senior Section Engineer, DLW,(Indian Railway)
Varanasi-221005, India
ABSTRACT:
An improved welding electrode for producing weld metal having low amount of hydrogen therein so that
hydrogen assisted cracking in weld zone is minimised. This is especially beneficial for welding high strength
steel having tensile strengths of about 70000 psi or above. The reduction of slag /metal reaction temperature
during welding have been found to have additional advantage of reducing the amount of oxygen in weld metal.
This provides increased impact properties for the weld metals. The filler metals that resist hydrogen related
cracking while also providing good mechanical properties. This paper deals with detailed study of low hydrogen
electrode comparing theoretical as well as practical aspects.
KEY WORDS: Low hydrogen electrode, HIC/HAC, Carbon Equivalent, SMAW, Preheat and Post heat weld
treatment
1. INTRODUCTION:
Low hydrogen electrode is an improved welding electrode for producing weld metal having low amount of
hydrogen therein so that hydrogen assisted cracking in weld zone is minimised[2]. Electrode classifications must
have a coating moisture level of less than 0.6% when tested at 1800 F (980 C), [5]. This moisture level
corresponds to a relatively low diffusible hydrogen level in the deposited weld metal, typically less than 16
ml/100g. For example, AWS A4.3, Standard Methods for Determination of Diffusible Hydrogen, shows that
when E7018 is welded at 70 F and 60% relative humidity a 0.6% coating moisture equates to approximately 12
ml/100g of diffusible hydrogen. A high hydrogen content in a tensile specimen can produce fisheyes on the
fracture surface as seen in Figure 1.

ISSN: 0975-5462

1211

Jyoti Prakash et. al. / International Journal of Engineering Science and Technology
Vol. 2(5), 2010, 1211-1220

Fig. 1 "Fish -eyes" on an all weld metal tensile specimen fracture surface

Hydrogen, however, does not typically influence the impact toughness, ultimate tensile strength or yield strength
results. It is only in severe cases that it can influence the ultimate tensile strength. Since low hydrogen SMAW
electrodes like E7018 are also required to have a minimum specified level of Charpy V notch (CVN) impact
energy, low hydrogen is sometimes equated with a minimum CVN level. This has led some people to specify
low hydrogen when the real desire is for notch toughness[15]. Some deposits with high hydrogen levels can
deliver relatively high levels of notch toughness. For example, the E6010 classification (non-low hydrogen, 3050 ml/100g) has a minimum CVN requirement of 20 ft-lbs at minus 20F. All of the electrodes that are
employed for flux cored arc welding (both gas shielded and self shielded),as well as SAW, are considered low
hydrogen[8]The word low is an imprecise description. The preferred method of controlling the level of
hydrogen in a weld deposit is to use the optional hydrogen designators as defined by the American Welding
Society. These designators are in the form of a suffix on the electrode classification (e.g., H8, H4, and H2) as
shown in Table 1. The filler metal manufacturer may choose to add the hydrogen designator to the electrode
classification if the filler metal meets the diffusible hydrogen requirements in the applicable AWS A5.x filler
metal specification.H2 level is a function of the microstructure susceptibility, constraint (or restraint), and
residual stresses. Microstructure susceptibility to hydrogen induced cracking often increases with increasing
steel strength. Therefore, for higher strength steels lower levels of hydrogen are required.

ISSN: 0975-5462

1212

Jyoti Prakash et. al. / International Journal of Engineering Science and Technology
Vol. 2(5), 2010, 1211-1220

Hydrogen is the absolute potential threat and most powerful enemy that deteriorates and leaves behind the
Weldment and/ or the Heat Affected Zone (HAZ) with Worm-holes (Gas -Pockets)/Porosities/ Pinholes/Cracks/Fissures/ Under bead Cracks, etc., from micro to macro levels, depending on the extent of its
availability in the arc atmosphere, weld metal pool (diluted) and with the parent metal[3]. Unlike Oxygen and
Nitrogen , Hydrogen does not form any Chemical Compound with Iron in the molten weld-pool .It, rather
remains dissolved in atomic state occupying the inter molecular spaces and interstitial positions of the molten
puddle and crystal lattices of the adjoining solid zones (of the HAZ) respectively. Very low 'Mass' of
atomic/molecular hydrogen and very high diffusion co-efficient are known characteristic features of hydrogen
with the combined effect of these two features, the mobility /diffusivity of hydrogen in the molten pool and
HAZ becomes extremely high. As a result, Hydrogen does not only remain dissolved in the molten weld puddle
to a super saturated /an appreciable extent, it easily migrates also into the hot solid parent metal adjacent to the
molten pool through the available solid-liquid interfaces. High temperatures of the HAZ increasingly alters the
positions of equilibrium atomic spacing of its structural constituents as a consequences of increase in the
amplitude of their thermal oscillations/vibrations and the elemental hydrogen thus migrates, with great ease, into
the interstitial of the crystal lattices of the constituents in the HAZ/Parent metal too. General Solubility of
Hydrogen in steel (Both molten and solidified) with changes in the steel temperatures, is shown in Fig.2).

ISSN: 0975-5462

1213

Jyoti Prakash et. al. / International Journal of Engineering Science and Technology
Vol. 2(5), 2010, 1211-1220

Fig. 2. Solubility of hydrogen in steel as a function of temperature

Hydrogen starts escaping out of the molten puddle in course of on-going welding itself, during
solidification of the weld -puddle and even over several-hours; after the weld -puddle has completely solidified.
This is due to decrease in its solubility with decrease in temperature of the Steel as depicted by Fig. 2, being
favoured as well by its said characteristic -features and thus, gives rise to unsoundness; resulting, obviously, into
inferior Mech. Strength and Toughness. Such escaping out/diffusing away of Hydrogen leads to formation of
'Pin holes/Worm-holes/Porosities (even in clusters)/ Surface cracks/Fissures/Under-bead Cracks' etc.
2. LOW HYDROGEN ELECTRODE AND RELATED FACTORS:
2.1. LOW HYDROGEN ELECTRODE:
i) L.H. Electrodes are primarily classified in terms of their 'Hydrogen Ratings', which is defined as-"The amount
of Diffusible Hydrogen content (Hd) present - in ml. per 100 gm. of Deposited Weld Metal". Broadly, they are
of three classes as stated hereunder. There are standard test methods also to evaluate this parameter and
IS:11802,BS: 6693 etc. refer to, for evaluating the Hd. Contents.
As per BIS Classification, these are Classes H1, H2 and H3, respectively (Ref. IS :814).
Class

Amount of Diffusible H2 Content

(ml/100gm)

10 to 15

II

5 to 10

III

Up to 5

Table 5. Different Class of Diffusible H2 Content

ISSN: 0975-5462

1214

Jyoti Prakash et. al. / International Journal of Engineering Science and Technology
Vol. 2(5), 2010, 1211-1220
ii)
The AWS (American Welding Society) do strongly recommend presence of this Devil (i.e. Moisture
Content) as 0.6% (max. ) in the flux coatings to get superior Mechanical Strength, Toughness and meet too
Stringent Radiographic Standards for such applications. .
iii)
It has been established that even as low a 'Hd' value of 5.5 can totally shatter a massive fabricated
structure of several tons, where maximum tolerable 'Hd' value is 5, though this extra 0.5ml of hydrogen /100 gm
appears to be absolutely insignificant in that matter. When thought of the massiveness of the structure.
iv)
To obtain superior weldments, it is preferred to use L.H. Electrodes with a high 'Coating Factor'
(Heavy Coating). For Heavy Coated types, the coating factors must be >1.5 These type of electrodes are the
most suitable electrodes for highly restrained and thick section joints.
v)
L.H. Electrodes are also of immense benefit while welding free cutting type of steels-containing high
levels of sulphur contents as deliberate additions; which otherwise, would have been left with substantial Gas
pockets/Porosities due to formation and escaping out of Hydrogen Sulphide, at and from the weldments and
HAZ, respectively.
vi)
So far as 'Under bead cracking' (Cold/Delayed Cracking) is concerned, lower the 'Hd' content, lower is
the possibility of 'under Bead Cracking.' Experiment based relationship in this regard, is shown in (Fig. 3)

Fig. 3. Relation Between H2 in Arc Atmosphere & Extent of Underbead Cracking

Relative Humidity prevailing in the surroundings. More the Relative Humidity, more the moisture/water-vapour
in the Weld-puddle and the HAZ would result into. The electrode has a filler wire core and flux covering of
predetermined constituents and low moisture levels such as below about 0.6 percent. The flux is bound together
with a binder of organic silicate (silica)which makes no substantial contribution to the moisture level of the
covering and which also makes the covering resistant to hygroscopic moisture pickup before the electrode is
used for welding.

ISSN: 0975-5462

1215

Jyoti Prakash et. al. / International Journal of Engineering Science and Technology
Vol. 2(5), 2010, 1211-1220

Fig. 4. Graph Between Absorbed Moisture & Exposure Duration

Thus ,this binder minimizes the amount of hydrogen from any moisture in the covering which may be
introduced into the weld metal during welding. Additionally, the flux covering contains a source of barium or
cesium in an amount effective to reduce the slag/metal reaction temperature during welding and due to this, the
amount of hydrogen actually introduced in to the weld metal from the electrode covering and binder is
minimized. This reduction in temperature has been found to have the additional advantage of reducing the
amount of oxygen in the weld metal. This provides increased impact properties for the weld metal[2].
2.2. PREHEATING AND POST WELD HEAT TREATMENT:
There are four primary reasons to utilize preheat: (1) It slows the cooling rate in the weld metal and base metal,
producing a more ductile metallurgical structure with greater resistance to cracking; (2) The slower cooling rate
provides an opportunity for hydrogen that may be present to diffuse out harmlessly, reducing the potential for
cracking; (3) It reduces the shrinkage stresses in the weld and adjacent base metal, which is especially important
in highly restrained joints; and (4) It raises some steels above the temperature at which brittle fracture would
occur in fabrication[14]. Additionally, preheat can be used to help ensure specific mechanical properties, such as
weld metal notch toughness. Welding codes generally specify minimum values for the preheat temperature,
which may or may not be adequate to prohibit cracking in every application. For example, if a beam to-column
connection made of ASTM A572-Gr50 jumbo sections (thicknesses ranging from 4 to 5 in [100-125 mm]) is to
be fabricated with a low hydrogen electrode, then a minimum prequalified preheat of 225F (107C) is required
[13].
Adequate 'Pre-heating' of the involved parts/members and 'Post-weld Heat -Treatment' of the weldment and
HAZ for ensuring slow heat dissipation, are of paramount importance. Such measures not only reduce
HAC/HIC but also diminish contraction-cracking, HAZ cracking etc. Simultaneously availability/induction of
free moisture in the arc atmosphere and HAZ is also minimized and 'Martensite' formation too, is totally
restricted by significantly low thermal-gradients, as such preheating should be carried out at 250C to 350C and
Post heating at 500C to 600C and for periods based on the Types of material, weldment-configuration ,
member thickness, etc.. Post heating is used to minimize the potential for hydrogen induced cracking (HIC). For
HIC to occur, the following variables must be present (see Figure 5) a sensitive microstructure, a sufficient level
of hydrogen, or a high level of stress (e.g., as a result of highly constrained connections)[12]

ISSN: 0975-5462

1216

Jyoti Prakash et. al. / International Journal of Engineering Science and Technology
Vol. 2(5), 2010, 1211-1220

Fig.5. Criteria For Hydrogen Induced Cracking (HIC).

After heat treatment, the properties of the deposited weld can be considerably different than the as welded
properties. For example, an E7018 deposit may have a tensile strength of 75 ksi (500 MPa) in the as welded
condition. However, after stress relieving, it may have a tensile strength of only 65 ksi (450 MPa). Therefore,
the stress relieved properties of the weld metal, as well as the base metal, should be evaluated[16] .Post heating
is not necessary for most applications. The need for post heating assumes a potential hydrogen cracking problem
exists due to a sensitive base metal microstructure, high levels of hydrogen, and/or high stresses. Post heating,
however, may be a code requirement. For example, ASME Section III and the National Board Inspection Code
(NBIC) both have such provisions. The Section III requirement for P-No. 1 materials is 450 to 550F (230 to
290C) for a minimum of 2 hours, while the NBIC requirement is 500 to 550F (260 to 290C) for a minimum
of 2 hours. Furthermore, post heating is often required for critical repairs, such as those defined under the
Fracture Control Plan (FCP) for Non redundant Members of the AASHTO[9].
2.3. HIC/HAC:
Hydrogen Assisted Cracking (HAC)" or "Hydrogen Induced Cracking (HIC)" can thus occur either in the
solidified Weld-Metal or the HAZ or both based on its diffusion mechanism together with the locked up stresses
due to contraction, welding restraints etc; over a long period of time. This is the reason for which, such defects
are also known as 'Delayed/Cold Cracking or Defect'. It is, therefore, wise and reasonable, as the general
practice is, to inspect such weldments and the adjoining HAZ; at least 48 Hrs. Later than complete solidification
of the molten weld- puddle. Such defects are influenced by three principal parameters/components, which are :a)

Presence of a certain level of adversely effective Internal-Stress

b)

A Susceptible (Resultant) microstructure

c)
The extent of Diffusible Hydrogen Content (Hd)-available in the arc-atmosphere, the Welding puddle
and HAZ/and /or the structural members involved.
2.4. CARBON EQUIVALENT AND WELDABILITY:
Pre-heating and Post weld Heat treatment are also equally important while welding Steels of poor 'Weldability
Potential' which is resulted into by high hardenability of such steels high hardenability is due to higher C
contents and /or Alloy additions like Cr, Mo, V,TI, Nb etc. The latter characteristic -feature is expressed by the
'Carbon Equivalent (CE) "Value of the Steel and C.E. Value of a Steel is calculated by the formula:C.E. = %C+% Mn/6 + (% Cr.+ % Mo+%V)/5 + (% Ni + %Cu)/15.

ISSN: 0975-5462

1217

Jyoti Prakash et. al. / International Journal of Engineering Science and Technology
Vol. 2(5), 2010, 1211-1220

Fig. 6. Interaction of Cooling Rate & Carbon Equivalency

Lower the 'C.E. value', better is the 'weldability Potential of the steel due to much less/no scope of Martensite
formation in the weldment and /or HAZ and vice-versa. Data based relationship between C.E. values and
Critical cooling Rate (C. C.R.) is shown in Fig. 6. With C.E. Value upto 0.35, Pre-hearing and Post weld Heat
treatment, though not absolutely essential, but takes care of HIC/HAC and with C.E. value above this;
HAC/HIC and Cracking due to high hardenability, are both taken due care of .Faster cooling rates promote
formation of 'Martensite' and increase its amount in the Weldment and the HAZ. Very high internal stress and
extreme brittleness of 'Martensite', have already been mentioned earlier.
3. EXPERIMENTAL WORK AND RESULTS:
Process

Wire/Electrode
Dia(mm)
1.6
5
5
2

MIG
SMAW
SAW
FCAW

UTS(MPa)

Elongation(%)

592
428
478
494

30.32
31.72
31.08
31.00

TABLE 6. Comparison of UTS (MPa) & Elongation(%) For Different Processes Without low hydrogen electrode

Process
7016 SMAW
7018 SMAW

Electrode Dia(mm)
5
5

UTS (MPa)
531
545

Elongation(%)
31.48
31.18

Table 7. UTS (MPa) & Elongation(%) Value For SMAW With low hydrogen electrode

C
Process
MIG
FCAW
SMAW

0.10
0.07
0.25(max)

CHEMISTRY OF WIRE AND WELD PAD

Element(%)
Si
Mn
P
0.92
0.53
0.35

1.5
1.18
1.5

0.014
0.012
.04

S
0.01
0.009
.04

Cu
0.24
----0.2(max)

Table 8. Chemistry of wire and weld pad

ISSN: 0975-5462

1218

Jyoti Prakash et. al. / International Journal of Engineering Science and Technology
Vol. 2(5), 2010, 1211-1220

Figure 7(a) &7(b) Bar graph without low Hydrogen Electrode in different processes
Figure 7(c) & 7(d) Bar graph with low hydrogen electrode in SMAW

On comparison among different processes(fig 7.a), we see that elongation % are nearly same for all the
processes and SMAW process give higher value than other but when we compare for ultimate tensile
strength(fig.7.b) then we get much difference between MIG welding and other processes as MIG process give
highest value(592MPa). When low hydrogen electrode is used (fig.7.c & 7.d)) then UTS increased from
428MPa to 531MPa(for 7016) and from 428MPa 545MPa(for 7018) for SMAW process which is closer to MIG
process. So we can say that SMAW process with low hydrogen electrode challenges the MIG process in some
cases.

ISSN: 0975-5462

1219

Jyoti Prakash et. al. / International Journal of Engineering Science and Technology
Vol. 2(5), 2010, 1211-1220
4. CONCLUSION:
When low hydrogen electrode is used then UTS increased from 428MPa to 531MPa(for 7016) and from
428MPa 545MPa(for 7018) for SMAW process which is closer to MIG process(592 MPa). On the basis of these
results we can use SMAW with low hydrogen electrode in place of costly MIG process which might be cost
effective in some cases . To ensure an interpass temperature of 2500C to 3000C and Peening of the solidified
Weld deposits with a sharp headed peening hammer after each pass, to release the locked up internal stresses
from solidification/contraction followed by removal of flux particles etc.., by thorough wire brushing and then
examine each bead by magnifying glass to ensure freedom from cracking. Ensuring religious adoption of all the
above -said measures, will result into very sound Weldments with no HAC/HIC as also no contraction cracks
etc. and with much Superior Mech. Properties (Including Toughness) and Radiographic standards.
5. REFERENCES:
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[15]
[16]

Robert OCon. Welding with Low Hydrogen Electrodes: A Look at the Past with Tips for Today. Practical Welding Today,:33-35,(
2000).
Jackson et al.,Low hydrogen welding electrodes,U S Patent :1978
B. Dasgupta, Key point on low hydrogen Electrode, Welding manual,DLS,VSKP
American Welding Society. Standard Welding Terms and Definitions. (ANSI/AWS A3.0-94):1994.
American Welding Society. Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding. (ANSI/AWS A5.1-91):(1994).
American Welding Society. Standard Methods for Determination of Diffusible Hydrogen Content of Martensitic, Bainitic, and Ferritic
Steel Weld Metal Produced by Arc Welding. (AWS A4.3-93) :16 (1993)
American Welding Society. Structural Welding Code Steel. (AWS D1.1:2000):( 2000)
Federal Emergency Management Agency. Interim Guidelines: Evaluation, Repair, Modification and Design of Welded Steel Moment
Frame Structures. (FEMA 267): 8-11(1995)
American Welding Society. Bridge Welding Code. (AWS D1.5-95),: 1995.
United States Military. Military Specification Electrodes Welding, Flux Cored, Ordinary Strength and Low Alloy Steel, (MIL-E24403/1D), :(1985).
American Bureau of Shipping. Rule Requirements for Materials and Welding,Part 2,:( 1997)
R. Scott Funderburk, Postweld Heat Treatment, Welding Innovation Vol. XV, No. 2:(1998)
The American Welding Society, ANSI/AWS D1.1-96 Structural Welding Code: Steel.:(1996).
R. Scott Funderburk ,Fundamentals of Preheat , Key Concepts in Welding Engineering, Welding Innovation Vol. XIV, No. 2, :(1997)
R. Scott Funderburk, Selecting Filler Metals: Low Hydrogen, Welding Innovation Vol. XVII, No. 1, :(2000)
AWS A5.5-96 Specification for low alloy electrodes for shielded metal arc welding, American Welding Society :1996

ISSN: 0975-5462

1220