Welding of HY-100

The following are the key changes in WPS (Weld Procedure Selection) when using HY-100

instead of ASTM A131 A: -

Welding Process Selection:

SMAW is preferred over FCAW due to superior fatigue crack growth resistance [a]. FCAW has

relatively higher heat input compared to SMAW. A higher heat input leads to the formation of

coarse pre-eutectoid ferrite/polygonal ferrite while, lower heat input promotes the formation of

acicular ferrite. The intra-granular formation of acicular ferrite results in the formation of randomly

oriented short ferrite needles with basket-weave feature. This interlocking nature coupled with the

fine grain size provides very good resistance to crack propagation. Also, acicular ferrite is

characterized by high angle boundaries between ferritic grains which offers an important resistance

to propagation of cleavage cracks. Also, SMAW doesnt require the use of shielding gas and the

equipment is simpler compared to FCAW.

Electrode Selection:

Low Hydrogen ferritic electrodes (E 10018 and E -11018) should be used for welding of HY-

100 and adequate precautions to keep them dry should be taken. Heating of electrodes in suitable

ovens to drive away any moisture should also be done. The above is required to avoid hydrogen

induced cracking. Note that the ampere (current) setting changes to 70-110 A for this electrode
[b]
(diameter remaining same) as recommended by the electrode supplier (M/s Lincoln Electric).

To maintain adequate heat input with current being reduced, the travel speed needs to be decreased.

Pre-heat Temperature Range:

The pre-heat temperature for HY-100 is 200F. Pre-heating is required to limit the formation of

untempered martensite which makes the joint brittle. Also, pre-heating allows hydrogen to diffuse
out of the weld zone and drives moisture away from the weld area thereby reducing the chances

of Hydrogen induced cracking and porosity. Additionally, pre-heating limits the formation of

thermal stresses and distortion that might happen due to the temperature gradient. The inter-pass

temperature should be kept below 300F so as to limit deterioration of properties in HAZ. The

increase in temperatures compared to previous material can be explained by the higher

hardenability (HY-100 has higher carbon equivalent compared to ASTM A131A due to greater

percentage of alloying elements), which means slower cooling rate is required to reduce

untempered martensite formation.

References: -

a) Effect of welding processes and consumables on fatigue crack growth behavior of armor grade quenched
and tempered steel joints by G. Magudeeswaran, V. Balasubramanian, G. Madhusudhan Reddy

b) http://www.lincolnelectric.com/en-us