International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:17 No:06 160

Control of Distortion by Combined Effect of DC-

LSND and TTT in MIG Weld Joints and Its Effect on
Residual Stress and Fatigue Behavior
Heri Wibowo1,2,*, M. Noer Ilman1, Priyo Tri Iswanto1, M. Rifai Muslih3
1
Department of Mechanical and Industrial Engineering, Universitas Gadjah Mada, Indonesia
2
Department of Mechanical Engineering Education, Yogyakarta State University, Indonesia
3
National Nuclear Energy Agency of Indonesia (BATAN), Serpong, Banten, Indonesia
*Corresponding author: e-mail address: heri_wb@uny.ac.id
Abstract-- The use of thin plates sections in fabrication of ship
hull structures for weight savings is preferable but it tends to
produce weld distortion. This current research aims to study
distortion and residual stress control methods by combining
dynamically controlled low stress no distortion (DC-LSND) and
transient thermal tensioning (TTT) techniques. These combined
‘in-process’ treatments were conducted by quenching the weld
metal behind the welding torch using cryogenic liquid nitrogen
and simultaneously performing the secondary heating process
using flame torches at both sides of the weldline. Subsequently, a
number of experiments was carried out as follows: distortion
measurement, residual stress measurement, microstructure
examination, hardness measurement, tensile test and fatigue test.
Results show that combined effect of DC-LSND and TTT
treatment can effectively reduce distortion and residual stress
which lead to improved fatigue crack growth performance. In
addition, changes in strength and hardness of the weld joints are
also observed and these are associated with changes in
microstructures due to secondary heating and quenching during
welding.
Index Term-- DC-LSND and TTT, MIG welding, distortion,
residual stress.
1 INTRODUCTION
Welding is the main manufacturing process in
fabrication of ship structures since the ship structures are built
from many thin plates or panels which are welded to form
structures. In recent years, thin plates in such constructions are
increasingly used to reduce weight, increase ship performance
with higher speed and lower fuel consumption. However,
welding of thin plates tend to result in welding distortion so
that welding repair is required. Distortion is undesirable
deformation caused by a localized heating and non-uniform
cooling during welding which produce thermal stresses. The
presence of distortion reduces dimensional accuracy, loss of
structural integrity and premature damage. In addition,
distortion can cause undesirable impact on the fabrication cost
since additional work or repair needs to be performed to
reduce weld distortion. The estimated cost of labor in
repairing and adjusting distorted element is 30% of the total
cost of labor [1].
Efforts have been made by a number research workers
with the aim of minimizing the weld distortion. In welding
process treatment based on mechanical effects such as
vibratory weld conditioning (VWC) technique [2] and
stretching technique [3] can significantly reduce residual
stresses and distortion in welded thin plate structures but these
techniques require high loads. Furthermore, thermal treatment
in welding process such as static thermal tensioning (STT) [4]
can minimize welding distortion and decrease the rate of
fatigue crack propagation [5] but this technique is less
effective especially for long plate which long secondary
heaters as well. Another known as the double-side arc welding
(DSAW) technique can effectively reduce distortion but
requires complicated equipment [6].
Transient thermal tensioning (TTT) is a technique for
control of weld distortion by employing secondary heat
sources placed at both sides of the weld line. TTT treatment
provides thermal tensioning effect which reduces distortion
and residual stress in weld metal [7][8] and it improves the
fatigue performance [5][8]. The advantage of TTT over post
weld treatments is an in-process weld heat treatment which is
carried out prior to or during welding hence reducing time for
weld preparation and and also cost. The intensity and position
of secondary heat sources in TTT affect the effectiveness of
distortion mitigation.
A relatively new technique to minimize welding
distortion is the dynamically controlled low stress no
distortion (DC-LSND). This technique is carried out by
spraying active coolant of CO2 snow [9][10] or liquid nitrogen
[11][12] behind the torch. The cooling process can reduce
temperature quickly and produce abnormal welding
temperature distribution that provides control of distortion and
residual stress. However, this technique has disadvantages
such as embrittlement of the weld metal [10].
In the present investigation, attempts have been made
by combining TTT and DC-LSND techniques to reduce
distortion and residual stress in welding of A36 steels.
2 MATERIALS AND METHODS
2.1 Materials and welding parameters
A metal inert gas (MIG) welding process was used to
join A36 carbon steel plates which have dimension of 400 x
100 x 4 mm. The weld groove was machined with the groove
angle of 30o, the root face of 2 mm and the root gap of 1.5
mm. The plates was prepared on a flat work table and welding
was applied without providing clamp on the workpiece. The
chemical compositions of the plates and the weld metals are
given in Table 1. The welding parameters used in these
investigations are shown in Table 2.

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Table I
The chemical composition of A36 steel and weld metal (wt%).
C Si Mn P S Cu Ni Cr Fe
A36 0.159 0.243 0.733 0.023 0.003 0.0137 0.016 0.042 Bal.
Weld metal 0.116 0.430 0.859 0.02 0.011 0.0834 0.014 0.035 Bal.

Table II
MIG parameters.
Voltage : 23.5 volt
Current : 148 A
Welding speed : 4.4 mm/s
Wire speed : 140 mm/s
Electrode type : ER70S-6
Diameter electrode : 0.8 mm

2.2 Combined treatment of DC-LSND dan TTT
The combined treatment of DC-LSND and TTT as shown
in Fig. 1 was performed by cooling the regions of both
adjoining plates behind the welding torch using double
cooling similar to that performed in the DC-LSND treatment
and simultaneously heating both sides of the torch at
temperature of 200 oC at the distance of 38 mm from the weld
line in a similar manner to that performed in TTT treatment.
Each cooling nozzle was located at the distance of 30 mm
behind the weld torch. The flow rate of nitrogen liquid used in
this investigation was 200 ml/minute. A partition was placed
between the cooling nozzles and weld torch to protect the
weld metal from negative effect of liquid nitrogen while the
secondary heating torches were located at various distances of
40 mm and 80 mm in front of the weld torch, and 60 mm
behind the weld torch. All treatment processes above are
designated as DT40, DT80 and DT(-60). The symbols of “D”
and “T” represent DC-LSND and TTT respectively, followed
by two digits of number which represent the distance variable.

(a)

(b)

Fig. 1. a The skematic of combined treatment of DC-LSND and TTT, b dimensional of combined treatments in mm.

2.3 Measurements of distortion indicator gauge, having the accuracy of 0.01 mm. The out of
After welding process, plates were marked with grids plane distortion along longitudinal direction was obtained by
with each dimension of 20 mm x 20 mm on the surface. The calculating the average distortion in longitudinal direction.
distortions were measured at all marked grids using dial

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2.4 Microstructure Examination 2.5 Hardness tests
Specimens were prepared through afour-step procedure Hardness measurements were performed along weld
as follows: cutting, grinding, polishing, and etching. metal (WM), coarse grain heat affected zone (CG-HAZ), fine
Examinations were focused on the weld metal area (WM) and grain heat affected zone (FG-HAZ), partially transformed
heat affected zone (HAZ). The quantitative analysis of region and unaffected base metal (BM) as shown in Fig.2.
microstructure was carried out by using point count according They were tested by Vickers micro hardness with a load of
to ASTM method [13]. This quantitative method obtained the 500 grf with the distance of 500 μm from one point to the
volume fraction of the microstructure in a particular area. other.

Fig. 2. Hardness measurement

2.6 Tensile tests metals. The specimens of this tensile testing were machined
Tensile tests were carried out along the longitudinal weld according to the standard of JIS Z2201 as shown in Fig. 3.
line direction to assess yield and ultimate stresses of the weld

Fig. 3. Longitudinal tensile test specimen

2.7 Fatigue crack growth tests fatigue crack propagation as follows:

 C K 
The fatigue crack growth rate (FCGR) tests were conducted da n
(1)
by sinusoidal loads with stress ratio (R) of 0.1 and frequency of dN
11 Hz. Middle tension M(T) specimens were used following the where da/dN is fatigue crack growth rate, ΔK is stress
ASTM E 647 standard as shown in Fig. 4. The crack propagation intensity factor whilst and C and n are constants.
was measured by traveling microscope with a level of accuracy
of 0.1 mm. Futhermore, Paris Law was used for analyzing

Fig. 4. Middle tension (M(T)) specimen

2.8 Measurements of residual stress Fig. 5. The measurements were taken in longitudinal, transverse
The measurements of residual stresses were performed and normal directions with wave length of neutron beam of
using the neutron diffractometer on 10 test points as shown on 1.836542 Å. The lattice plane used in this investigation was 211

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o
direction and the diffraction angle of 103 . The strain lattice (εi)
was obtained from the change in planar spacing with the strain-
free spacing (do) as the referrence using Eq 2.
i  i
d  d0
(2)
d0
where di is inter planar spacing where i is x,y,z direction, d0 is
strain free inter planar spacing.
Residual stresses (σi) were obtained by considering the strain
Fig. 5. Neutron test points of the residual stress measurement
3 RESULTS AND DISCUSSION
3.1 Thermal cycles
Fig. 6 shows the welding thermal cycle during a
welding process on the combined treatment of DC LSND and
TTT that extracted from the thermocouple data. Based on the
thermal cycle graph, in the area of 5 mm from the welding
center, there is a cooling effect on DC-LSND which will
accelerate the cooling process up to 500 0C. The cooling
process can be analyzed interpolagraphically, which will result
in the cooling rates from 800 0C to 500 0C on the DT40
treatment around 10.5 seconds and on the DT80 treatment
around 10.0 seconds. Compared to the cooling rate on as-
welded of 19 seconds, the combined treatment of DC-LSND
and TTT can accelerate the cooling rate in the area
surrounding the weld line. Based on the continuous cooling
transform (CCT) diagram [14], phenomenon of the change of
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lattice, Poisson’s ratio and Young’s modulus using Hooke’s
equation as follows:
i 
Ehkl
1  vhkl 1  2vhkl 
 
1  vhkl  i  vhkl  j   k  (3)
where Ehkl is Young’s modulus and vhkl is Poisson’s ratio.
cooling speed will affect the micro structure and mechanical
strength of the weld.
The combined treatment of DC-LSND and TTT will
change the temperature distribution in the area surrounding the
weld line, particularly during the cooling process as shown in
Fig. 7. Cooling process and plate equalization temperature
strongly influence the level of distortion. This phenomenon is
aligned with some papers [8][15] which suggest the degree of
distortion and residual stress interconnected and affected by
the distribution of welding temperature. This study found that
the DT(-60) treatment tends to stabilize the temperature
around the weld metal compared to other treatments especially
those with the distance of 15 and 30 mm.This will affect the
distortion and residual stress becomes low after the welding
process.
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(a) (b)

(c) (d)

Fig. 6. Welding thermal cycles on: a As-welded, b DT40, c DT80, and d DT(-60)

Fig. 7. Welding temperature distribution at cooling process on combined treatment of DC-LSND and TTT

3.2 Weld distortion
Fig. 8 shows the out-of-plane distortions of welded
plates produced with and without the combined treatment of
DC-LSND and TTT at various welding torch distances. It can
be seen all welded plates are suffered from out of plane
distortion which have convex shape with the maximum
distortion occurs in the middle of plate length. The combined
treatment of DC-LSND and TTT can reduce out-of-plane
distortion significantly. The lowest distortion is achieved by
the welded plate produced using the DT(-60) treatment with
the distortion around 3.3 mm or 65,5 % lower compared to
that present in as-welded welded plate which has the

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maximum distortion of 9.60 mm. Although combined DC- significantly decrease the out of plane distortion. Combined
LSND and TTT treatment with the welding torch in front of treatment of DC-LSND and TTT generate more stretching
weld metal i.e. DT40 dan DT80 is proved to reduce distortion effects than that of single treatment which oppose buckling
but its effectiveness is not as good as one with the welding distortion during welding process.
torch placed at the back of the weld torch, i.e. DT(-60) can

Fig. 8. Out of plane distortion in the combined treatment of DC-LSND and TTT

3.3 Microstructures
Fig. 9. shows the microstructures of the weld metal on
as-welded condition and treated using combined DC-LSND
and TTT. It shows that changes of micro structures occur,
which can be examined by the type and size of grain due to
these treatments.
The microstructure of weld metal on all welds in Fig. 9
exhibits acicular ferrite (AF), Witmanstatten ferrite (WF) and
grain boundary ferrite (GF). The as-welded condition shows
the dominant phase of GF. The application of combined
treatment of DC-LSND and TTT seems to change the size and
volume phase of microstructures but it still presents similar
microsturctures. The combined treatment of DC-LSND and
TTT have refined the size and increased the percentage of AF
more than as-welded condition. These treatments also reduced
the percentage of GF and changed some plates of WF. Some
works [16][17] reported that the phase change of the
microstructure is greatly influenced by the cooling rate. The
change of the phase is also supported by the measurement
results of the thermal cycle during welding (Fig. 6) which
shows the cooling time (Δt8/5) on combined treatment of DC-
LSND and TTT less than as-welded condition.
3.4 Hardness distribution
The results of the hardness measurement across weld
metal (WM), heat affected zone (HAZ), partially transformed
region and base metal (BM) are shown in Fig. 10. The HAZ
can be devided into coarse-grained (CG) and fine-grained
(FG) HAZ. In all welded joint specimens under study, the
hardness of weld metals are relatively higher than the base
metal and sharp increase in hardness occur at HAZ then the
hardness decreases gradually as the distance is away from the
HAZ and then the hardness becomes constant at BM. The
combined treatment of DC-LSND and TTT increase the
hardness of WM. The relatively high values of hardness in
WM are related to the high percentage of AF microstructureas
a result of increasing of the cooling rate. This statement is
corresponds with Sivaraos et al. [18] that microstructure is the
main factor influencing the hardness.

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Fig. 9. Weld metal (WM) microstructures at : a As-welded, b DT80, c DT40, and d DT(-60)

Fig. 10. Hardness distribution on weld joints of A36 steels

3.5 Tensile Stresses
Fig. 11 shows the results of the longitudinal tensile
tests for the weld joints in as-welded condition and the
combined DC-LSND and TTT treatment. Weld metal is as
welded condition has strentgh of 567 MPa and yield stress of
400 MPa. The strengths of weld metals treated using DT40
and DT80 with the heating in front of the torch are similar to
that of as-welded weld joint. However, the treatment of DT(-
60) with the heating at the back of the torch significantly
increase tensile strength of about 567 MPa. This indicates that

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the combined treatment of DC-LSND and TTT with the associated with the increasing percentage of AF in the weld
heating at the back of the torch the welding acts as postweld metal as supported by the number of works [19][20].If related
tends to be able to improve the tensile strength compared to to the microstructure of the weld metal on the combined
when it functions as the preheat. The high tensile stresses treatment of DC-LSND and TTT, the percentage of AF is
under the combined treatment of DC-LSND and TTT are linear with its tensile strength.

Fig. 11. Tensile strength of weld joints in longitudinal direction

3.6 Fatigue crack growth rate function of the number of cycles (N) as shown in Fig. 12. It can
The fatigue crack propagation is measured in weld metal be observed that combined effect DC-LSND and TTT treatment
area and presented by plotting the crack length (a) as the increase the fatigue life of the weld joints.

Fig. 12. Diagram of a-N function

Furthermore, the a-N curves can be analyzed in the form of the combined treatment of DC-LSND and TTT has a lower
fatigue crack propagation rate (da/dN) as the function of the value than the as-welded condition. This crack propagation
stress intensity factor range (ΔK) as shown in Fig. 13. It shows retardation is likely to be associated with residual stresses and
that at the beginning of fatigue crack propagation, the da/dN of this will be discussed in further section. Fatigue crack

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propagation rates (da/dN) in stable crack region (region II) is 3. The results of da/dN indicate that the combined treatment of
usually represented by Paris law (equation 1). DC-LSND and TTT have a lower fatigue crack growth rate than
Fatigue crack propagation rate can be determened by the as-welded condition at all ΔK values. This finding is relevant
taking the trend lines of da/dN - ΔK curves at region II which with the work of D’Urso, et al. [21] which states that weld
have the slope of n and C value at the intersection with the da/dN treatment affects the crack propagation rate at low ΔK.
axis at ∆K=1 MPa√m. The values of n and C are given in Table

Fig. 13. Fatigue crack growth rate of welded joints

Table III
Paris constants
Environment C n
As-welded condition 1.3286E-12 3.585
DT(-60) treatment 3.4784E-13 3.921

The SEM fractography on welded joints of as-welded crack are observed. Striations, typical of fatigue fracture are
condition and the combined treatment of DC-LSND and TTT not clearly seen. Fractured surface of the combined treatment
is shown in Fig. 14. In as welded condition, fractured surface of DC-LSND and TTT striations like appearance.
seems to be brittle cleavage fracture with a little secondary

Fig. 14. SEM micrography of: a as-welded condition, b DT(-60) treatment

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3.7 Residual stress
The longitudinal dan transverse residual stresses
measurements were done along the transverse distance from
the weldline. The combined DC-LSND and TTT treatment
with the secondary heating sources located at the distance of
60 mm behind the weld torch, i.e. DT(-60) treatment was
selected in this investigation because it effectively reduces
weld distortion.
Fig. 15 a shows longitudinal residual stresses in as-welded
condition and the combined DT(-60) treatment. In general,
both welded plate specimens show tensile residual stress in
weld region and its adjacent area and whilst the regions away
from the weldline form compressive residual stress static
equilibrium.
Fig. 15 b shows the transverse residual stress in as
welded condition and the weld treated with combined DC-
LSND and TTT treatment. It can be seen that the tensile
residual stress at the weld centre, i.e. 185 MPa as shown in as
welded condition is reduced 110 MPa due to combined DC-
LSND and TTT treatment.. The decrease of the tensile
residual stress was caused by the change of the gradient
temperature as a result of the cooling treatment on DC-LSND
as suggested by by Guan [22]. As disscussed previously, the
magnitude and distribution of residual stress influence fatigue
behavior. It can be argued that better fatigue crack growth
resistance in the the weld treated using combined DC-LSND
and TTT is caused by its lower transverse residual stress present
in the weld region as shown in Fig. 15. The condition of stresses
at the crack tip can be seen from stress intensity factor, K. Based
on superposition approach, the total stress intensity factor Ktotal
is the sum of stress intensity factor due to residual stress, Kres and
that generated by applied stress, Kapp. Accordingly, low (or even
compressive) residual stress will reduce Ktotal hence reducing
fatigue crack growth rate.

(a)

(b)

Fig. 15. Results comparison of residual stress in : a longitudinal direction, b transverse direction

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