Heat treatment of welded structures

HEAT TREATMENT
Why?
Improve mechanical properties Change microstructure Reduce residual stress level Change chemical composition

How?
Flame oven Electric oven/electric heating blankets induction/HF heating elements

Global

Where?

Local

HEAT TREATMENT METHODS

Advantages:
Easy to set up Good portability repeatability and temperature uniformity

Disadvantages:
Gas furnace heat treatment Limited to size of parts

HEAT TREATMENT METHODS

Advantages:
Ability to vary heat Ability to continuously maintain heat

Disadvantages:
Elements may burn out or arcing during heating

Local heat treatment using electric heating blankets

HEAT TREATMENT METHODS

Advantages:
High heating rates Ability to heat a narrow band

Disadvantages:
High equipment cost Large equipment, less portable

HF local heat treatment

HEAT TREATMENTS
The inspector, in general, should ensure that:

Equipment is as specified Temperature control equipment is in good condition Procedures as specified, is being used e.g.
o o

Method of application Rate of heating and cooling

o
o o

Maximum temperature
Soak time Temperature measurement (and calibration)

DOCUMENTATION AND RECORDS

HEAT TREATMENTRecommendations

Provide adequate support (low YS at high temperature!) Control heating rate to avoid uneven thermal expansions Control soak time to equalise temperatures Control temperature gradients - NO direct flame impingement! Control furnace atmosphere to reduce scaling Control cooling rate to avoid brittle structure formation

HEAT TREATMENTS
Many metals must be given heat treatment before and after welding. The inspectors function is to ensure that the treatment is given correctly in accordance with the specification or as per the details supplied.

Types of heat treatment available:

Preheat Annealing Normalising Quench Temper Stress

Hardening

Relief

HEAT TREATMENTS
Pre-heat treatments

are used to increase weldability, by reducing sudden reduction of temperature, and control expansion and contraction forces during welding

Post weld heat treatments

are used to change the properties of the weld metal, controlling the formation of crystalline structures

HEAT TREATMENTS
Preheat:

We can preheat metals and alloys when welding for a number of reasons. Primarily we use most pre-heats to achieve one or more of the following:

To control the structure of the weld metal and HAZ on cooling

To improve the diffusion of gas molecules through an atomic structure. To control the effects of expansion and contraction. Preheat controls the formation of un-desirable microstructures that are produced from rapid cooling of certain types of steels. Martensite is an undesirable grain structure very hard and brittle it is produced by rapid cooling form the austenite region.

HEAT TREATMENTS
Preheat temperatures are arrived by taking into consideration the following:

The heat input

The carbon equivalent (CE)

The combined material thickness The hydrogen scale required (A, B, C, D)

HEAT TREATMENTS
Pre-Heat Requirements
The welding heat input Increased - Reduced

Carbon Equivalent Increased - Increased

Hydrogen content Increased - Increased Combined material thickness Increased - Increased

HEAT TREATMENTS
The temperatures mentioned are for steels: Process: Temperature: Cooling: Result: Pre-heat for welding
50-2500C. higher by exception Hold during welding. Prevents cracking and hard zones

HEAT TREATMENTS
Advantages of preheat:
Slows down the cooling rate, which reduces the risk of hardening Allows absorbed hydrogen a better opportunity of diffusing out, thereby reducing the risk of cracking Removes moisture from the material being welded Improves overall fusion characteristics

Lowers stresses between the weld metal and parent material by ensuring a more uniform expansion and contraction

METHODS OF MEASURING PREHEAT

Temperature indicating crayons (Tempil sticks) Thermocouples or touch pyrometers At intervals along of around the joint to be welded

The number of measurements taken must allow the inspector to be confident that the required temperature has been reached
In certain cases the preheat must be maintained a certain distance back from the joint faces If a gas flame is being used for preheat application the temperature should be taken form the opposite side to the heat source If this is not possible time must be allowed before taking the preheat temperature e.g 2 mins for 25mm thickness

Post Weld Heat Treatment

Question:
What is the main reason for carrying out PWHT (to steel joints) ?

Answer:
To reduce residual stresses

Supplementary Question:
What is the benefit for reduce residual stresses ?

Supplementary Answer:
To improve resistance to brittle fracture

Post Weld Heat Treatment

Removal of Residual Stress
Cr-Mo steel - typical Yield Strength (N/mm2 ) 500 400 300 200 100 100 200 300 400 500 600 700

C-Mn steel - typical

At PWHT temp. the yield strength of steel reduced so that it it is not strong enough to give restraint. Residual stress reduced to very low level by straining (typically < ~ 0.5% strain)

Temperature (C)

Post Weld Heat Treatment

PWHT Procedures - Basic Requirements
Maximum Heating Rate usually from 300 or 400C - need to avoid large temp. gradients that may cause distortion/cracking

max. rate depends on thickness but typically up to ~ 200C/h

Soak Temperature depends on steel type - usually specified by Code (~550 to ~750 C ) Minimum Soak Time need to make sure and whole item/full thickness reaches specified temp. Codes typically specify 1h per 25mm related to max. joint thickness Maximum Cooling Rate usually down to 400 or 300C - for same reasons as controlled heating rate

HEAT TREATMENTS

Any Questions

QUESTIONS
Heat Treatments QU 1. How can the levels of hardness be controlled in the HAZ? QU 2. What is the maximum recommended heat treatment temperature for steel weldments? State which heat treatments may be considered when maximum toughness is required QU 3. What are the four main considerations for determining preheat temperatures, and as a welding inspector which factors require inspection when applying pre-heat to a carbon steel joint to be welded? QU 4. What factors need to be checked/controlled during a heat treatment process QU 5. Which heat treatment process is required when maximum ductility is required for example for extensive cold working operations.