Material for May 6th 2010

Structure of the welded joint

and Cracking phenomena in steel weld

Lecturer Dr. Jippei Suzuki Graduate School of Engineering Mie University Department of Mechanical Engineering Faculty of Engineering, Mie University Kurima-Machiya-cho 1577, Tsu, Mie 514-8507 Tel. 059-231-9372 Fax. 059-231-9663 E-mail jsuzuki@mach.mie-u.ac.jp

Thermal history of welds (Fig.A1)

Heat source arc laser electron beam

Heat conduction Intensity of heating Heat input H= EI

Magnitude of cooling 60 Heat conduction 1. Thermal conductivity 2. Plate thickness 3. Joint type 4. Preheating temperature Heat loss Arc efficiency Sielded metal arc welding 77-87%(steel) Submerged arc welding 77-99% TIG welding 68-85% MIG welding 66-69%(steel) 70-85%(aluminum)

H: heat input [ joule/cm] E: arc voltage [V] I: welding current [A] v: welding speed [cm/min]

Microstructure of weld depends on the position (Fig.A2)

Weld metal Unaffected base metal Heat affected zone; HAZ Carbon content of the steel a b Temperature -ferrite -austenite Eutectic reaction LFe3C Eutectoid reaction Fe3C

d c b a

Peritectic reaction

c
d -ferrite Time Carbon content

Construction of steel weld (Fig.A3)

HAZ heat UAZ Melting
electrode & base metal plate

Weld metal

Heating

base metal plate

Weld metal;

melting point

Solidification
weld metal

composite region unmixed zone

Cooling (transformation of to )

Weld interface Heat affected zone

partially-melted zone true heat affected zone coarse grain zone; 1250 mixed zone; 1250 1100 fine grain zone; 1100 900 granular pearlite zone;900 750 (embrittled zone); 750 200

formation of

Weld metal

formation of

Heat Affected Zone (HAZ)

Un-affected zone; 200 room temp.

Microstructure of steel weld (Fig.A4)

Weld metal reheated by subsequent pass

Weld metal

Fusion boundary Base metal

C Base metal Weld metal 0.12 0.08 Si 0.23 0.52 Mn 1.09 0.83 P 0.019 0.012

Heat affected zone

S 0.006 0.009 N 0.004 0.008 O 0.008 0.033

Examples of weld solidification structure of mild steel (Fig.A5)

Axial crystal

Stray crystal

Columnar crystal

Equiaxed dendrite

TIG welding, Heat input 4.3kJ/cm, Welding speed 10100cm/min Base metal JIS-SS400, 0.18C-0.06Si-0.60Mn-0.015P-0.02S

Two microstructures Structure formed during solidification Structure formed by solid state transformation
Weld metal

Equilibrium diagram for Fe-C(Fe3C or graphite) system (Fig.A6)

Temperature

mass % of Carbon

Solidification of molten metals (Fig.A7)

grain

nuclei
Molten metal (a) grain

(b) grain

(c)

(d)

grain boundary

Growth of grain - dendritic crystal (Fig.A8)

[001] [111]

Liquid Solid

[100]
[010]

[010]

[100] [001] [001]

[110]

[010] [100]

Distribution of liquidus temperature near the solid-liquid interface (Fig.A9)

Equilibrium distribution coefficient; k0CS/CL
solid CS Microsegregation of solute element during solidification CL C0 1
Solute concentration Solute concentration

k0<1 liquid

liquid

k0>1
solid

CL

CL

CS

Solute concentration

Solute concentration

1k0 R exp X DL k0
liquid

solid CL C0 k0

C0 k0 C0

distance
liquid-solid interface

C0

distance
liquid-solid interface

Constitutional supercooling (Fig.A10)

Solute concentration in liquid

CL C0
Distance from the interface

Solid-liquid interface constitutional supercooling thermal gradient G Temperature

TL

Temperature

C0

CL
Solute concentration

Distance from the interface

Microstructure formed during solidification (Fig.A11)

Some types of solidification structures Planar interface Cellular interface Cellular dendritic interface Columnar dendritic interface Equiaxed crystal
The solidification structure depends on the solidification parameter; G and the concentration R of solute element; C0, where G is the thermal gradient, and R is moving speed of solid-liquid interface.

Thermal gradient Temperature Melting point (liquidus temperature)

Weld bead

Welding speed of V RiV cosi

Solid-Liquid interface

Planar interface and cellular interface (Fig.A12)

Planar interface
Base metal plate Weld metal

G; thermal gradient temperature

TL; liquidus temperature

Distance from the interface
liquid-solid interface

Growth by planar interface near weld center of TIG-arc weld metal of 99.99% pure Al thin steet (Welding speed; 25cm/min)

liquid-solid interface

Cellular interface

cross-section of subgrain

temperature

G TL

Example of cell in weld metal of HY 80

Distance from the interface

Cellular dendritic interface (Fig.A13)

temperature

Competitive growth near fusion boundary in TIG arc weld metal of Al thin sheet

Corrugation on surface of TIG arc weld metal of Al thin sheet

G TL

Distance from the interface

Columnar dendritic interface and Equiaxed dendritic crystal (Fig.A14)

Columnar dendritic interface

temperature

G TL

Distance from the interface

Equiaxed dendritic crystal temperature TL G

Distance from the interface

Characteristics of solidification in the weld pool

Two rules concerning with solidification 1. Molten metal solidifies along the direction of maximum thermal gradient. 2. The solidification rate depends on the crystalline direction. In the case of cubic crystal, the solid crystal grows in the direction of <100>.

Characteristics of solidification of weld pool 1. Epitaxial grow 2. Change in the direction of maximum thermal gradient

Competitive growth Stray crystal

Epitaxial growth and competitive growth (Fig.A15)

Liquid metal

Higher temp.

a2 a1 b1 b2

a3 a4

direction of maximum thermal gradient

Lower temp. <100> Solid crystals Examples of pitaxial growth

Epitaxy
Growth of one crystal on the surface of another crystal in which the growth of the deposited crystal is oriented by the lattice structure of the substrate.
McGraw-Hill Dictionary of scientific and technical terms

Epitaxy
Growth of a crystalline substance on a substrate crystal, in which the substrate determines the crystal structure adopted. Since crystal structures vary in lattice parameter and crystal type, quite apart from variations in atomic radius, it is obvious that epitaxial growth must be restricted, and that considerable stresses may be generated even when it occurs. In general, the two lattices involved (substrate and deposit) should be reasonably commensurate, the binding energy should not be too dissimilar, and in ionic substances, the arrangement of positive and negative ions should be capable of similar alignment.
Macdonald and Evans, The Metals Society, C.R.Tottle, An Encyclopaedia of Metallurgy and Materials

Solidification of weld puddle (Fig.A16)

The crystals prefer to growing along the direction of the maximum thermal gradient. While, the crystals have the direction of maximum growing rate, for example, 1 0 0.

Weld puddle

Speed of solidification welding speedconstant Center line of the weld metal

arc

Weld bond

Speed of solidification is smaller than welding speed, and increases upto welding speed. And the direction of maximum thermal gradient changes.
Moving speed of liquid-solid interface i0 RVcos 0 V

Center line of the weld metal

RVcos

0 2

RV cosi

Behavior of growing columnar crystal (Fig.A17)

Stray crystal

Competitive growth

direction of maximum thermal gradient

a1

a2

a3

a4

Growth of columnar crystal in the weld puddle (Fig.A18)

Shapes of the puddle Elliptical shaped (low speed welding)

Low speed welding(25cm/min)

Parabolic shaped(medium speed welding)

Teardrop shaped(high speed welding)

High speed welding(150cm/min) Examples of growth of columnar crystal in TIG-arc weld metal of Al thin sheet

Hot cracking
Hot crack occurs in the weld metal during solidification.
Base metal plate

Solidification of molten metal Contraction (shrinkage) Gap or crevice in the weld metal New molten metal flows into the gap Occurrence of thermal stress

Melted region

Solidifying range (Fig.A19)

Weld puddle

Welding arc C0

Temperature

Solute Concentration

Temperature

Position

Borlands theory (Fig.A20)

Temperature

Coherent temperature Critical temperature Stage 1 Stage 2 Stage 3

Stage 1 Solids can move without restraint. Coherent temperature Stage 2 Solid crystals contact each other, but liquid regions are connected three dimensionally Critical temperature Stage 3 Isolated liquid region begins to form, and new liquid can not flow into that region.

Critical Solidification Range (CSR) Width of

Solute content

Sensitivity to hot cracking of aluminum alloys (Fig.A21)

Temperature

High sensitivity Difficult to weld

Medium sensitivity possible paying attention

Low sensitivity possible to weld

Hot cracking in carbon steels (Fig.A22)

Peritectic reaction in Fe-C system L+ C0

Microsegregation during solidification L

Temperature

Segregation due to peritectic reaction

Carbon content

Sensitivity to hot cracking of steel (Fig.A23)

Temperature

Temperature range of solidification

C0 mass% Solute content mass%

Temperature

Substance with low melting point Fe-S system FeS, FeS2 Fe-P system Fe3P