Carbon steels
Low alloy steels (Cr - Mo steels)
Quenched tempered steels
High alloy steel
Carbon steels
Low Carbon steels
<0.30 %C max.
Medium Carbon
Steel
0.30-0.65 %C
>1.8%C
Cr-Mo steels
Low alloy ferritic steel
- High temp application
- Pr vessels , Nuclear application
- Reactor vessel in refinery
Cr
Mo
Mn
Cr-1/2 Mo
0.10-0.20
0.50-0.80
0.45-0.65
0.30-0.60
1Cr-1/2 Mo
0.15
0.80-1.25
0.45-0.65
0.30-0.60
1 Cr-1/2 Mo 0.15
1.00-1.50
0.45-0.65
0.30-0.60
2 Cr1/2 Mo
0.15
1.65-2.35
0.45-0.65
0.30-0.60
2 Cr-1 Mo
0.15
1.90-2.60
0.87-1.13
0.30-0.60
3 Cr1 Mo
0.15
2.65-3.65
0.80-1.06
5 Cr1/2 Mo
0.15
4.00-6.00
0.45-0.65
9 Cr 1Mo
0.15
8.00-10.00
0.90-1.10
8.00-9.50
0.85-1.05
9 Cr1 Mo Nb V 0.08-0.12
Cr- Mo steels
Type
Forging
pipe
Plate
Cr-1/2 Mo
A182-F2
A 335 P2
A387Gr 2
1Cr-1/2 Mo
A182 F12
A336 F12
A335 P12
A387 Gr 12
F182 F11
A335 P11
A387 Gr 11
A336 F11
A369 FP11
A 182 F22
A335 P22
A336 F22
A369 FP22
A369 FP12
A426 CP12
1 Cr-1/2 Mo
2 Cr-1 Mo
A387 Gr 22
Type
Forging
pipe
Plate
3 Cr 1Mo
A182 F21
A335 P21
A387 Gr 21
A336 F21
A369 FP21
A182 F5
A335 P5
A336 F5
A369 FP5
5 Cr-1/2 Mo
5 Cr MoSi
A335 P5b
5 Cr Mo Ti
A335 P5c
7 Cr-1/2 Mo
A182 F7
A335 P7
A387 Gr 5
A387 Gr 7
A369 FP7
9 Cr1Mo
9 Cr1 MovNbN
A 182 F9
A335P9
A336 F9
A369 FP9
A182 F91
A335 P91
A369 FP91
A387 Gr 9
A387 Gr 91
Weldability
Steel composition
Microstructure
Welding process
Weldability of steels
Carbon influences weldability
Alloy element influence weldability
C eq- C+Mn/6+(Cr+Mo+V)/5 + (Cu +Ni)/15
Martensite
Bainite
Ferrite
Pearlite
Bainite
Carbon steels
Low alloy steels
Stainless steels
Aluminimum
Dissimilar metals
Differing melting temp
MIG
Problems
Hydrogen cracking
Solidification cracking
Lamellar tearing
Hydrogen crack
Cold crack
Delayed crack
Underbead crack
Hydrogen cracking
Ductility
Hardness
Crack
sensitivity
70
60
50
40
30
20
0
0
0.1
0.2
0.3
0.4
0.5
0.6
%C
0.7
0.8
0.9
Diffusible hydrogen
Susceptible microstructure
Tensile stress
cracking
Cracking mechanism
Hydrogen dissociation ( H2
H+H)
Cracking mechanism
Hydrogen solubility is high in liquid state
Upto the solubility limits present in interstial
solution
Beyond the solubility limit, retained in traps.
Localisation of hydrogen takes place
Adsorption of hydrogen reduces the surface
energy required for crack initiation
1.6
1.2
Liquid Fe
0.8
Gamma Fe
0.4
Alpha Fe
0.2
0.0
1600
1000
600
400
Temp C
Sources of hydrogen
Flux coating material in electrodes & SAW
welding Flux
Consumables exposed to atmosphere
Moisture in shielding gas
No/ improper baking of weld consumables
Hydrocarbons in base metal
Rusted consumable / base metal
Cracking threshold
Stress Mpa)
2 ppm
4 ppm
8ppm
4
12
Time (h)
16
20
24
Pre-heat
0.40
Carbon Content %
0.30
ZONE II
ZONE III
0.20
0.10
ZONE I
0.00
0.20
0.30
0.40
0.50
0.60
0.70
Carbon Equivalent CE
Microstructure
Composition of steel
Processing route
Composition of weld
metal
Welding conditions
nil
80 deg
Preheat
120
nil
12
Tensile stress
Restraint
Thickness
Improper fit up
Rapid cooling
To avoid hydrogen
cracking
Preheating
Post heating
Baking of electrodes
prior to welding
Rutile electrode 250 C
Basic electrode 350 C
Preheat
Carbon equivalent
Thickness of the base metal
Diffusible hydrogen content
Restraint
Welding process, consumable &
conditions
Preheat
Preheat
No welding on the base metal covered with ice
No welding shall be done at or below - 18 deg C
Raise the base metal temperature to min. 16 C
when the ambient temp is 0 to - 18 deg c
Preheat temperature shall be measured at a
distance of 2t or 4 which is higher
Preheat temperature shall be maintained during
welding
F= 47 Si + 75 Mn + 30 Ni + 31 Cr
200
HEAVY RESTRAINT
LOW RESTRAINT
50
Preheat temp C
%C
0.35
0.25
300
500
hardness
> 225 = M
13 to 25 mm
25 mm
Temp In Deg C
Cr-1/2Mo
38
93
149
1Cr-1/2Mo
121
149
149
11/4Cr-1/2 Mo
121
149
149
2Cr -1/2Mo
121
149
149
21/4Cr-1Mo
121
149
149
3 Cr1 Mo
149
177
177
5Cr-1/2 Mo
149
177
177
7 Cr1/2 Mo
149
177
177
9Cr-1Mo
9C1Mo V NbN
149
177
177
177
204
204
Solidification
cracking
SOLIDIFICATION CRACKING
- Cracking occurs at high temperature close to
liqudus temp.
- Fully Austenitic weld metal are more susceptible
- Hot cracks may be macro cracks or micro cracks
Causes
- Segregation of impurities to the interdentritic regions
- Formation of low melting eutectic along the grain
boundary
- Shrinkage stresses
Lamellar
Tearing
Lamellar Tearing
Tee Joint
Lamellar
Tear
Corner Joint
Fillet Weld
Lamellar Tear
Step like crack
in HAZ
Lamellar tearing
Causes
High tensile
stresses
parallel to
weld
Stringer type
inclusions in
base plate
Presence of
Diffusible
Hydrogen
Lamellar Tearing
Material
anisotropy
Poor Short Transverse
ductility
Inclusions
Restraint
stress
Joint thickness
Joint Design
Welding Procedure
Inclusions
Type of inclusions
Sulphides
Oxides
Oxy sulphides
Silicates
Volume fraction
Mean spacing between inclusion
ASME spec.
Temp Limit
( C)
Carbon steel
SA 178 , SA 210 ,
SA 192
454
Carbon + 1/ 2 Mo
SA 209 T1
480
1 Cr Mo
SA 213 T 11
550
2 Cr 1 Mo steel
SA 213 T22
580
25 Cr 20 Ni
1050
FCAW 5.20
SMAW
GMAW
Cr-1/2 Mo
E 80xx-B1
FCAW
E7XT5 A1
SAW
F8XX EXXX B1
E8XT1-A1
1Cr-1/2 Mo
E 801XB2
ER 80X B2 E8XTX B2
F8XX EXXX B2
1 Cr-1/2 Mo
E 701XB2L
ER 70XB2L E8xTXB2L
E8XTXB2H
2 Cr-1 Mo
E901X B3
ER 90XB3 E 9XTXB3
E 801X B3L
ER 80X B3LE9XTXB3L
F9XX EXXX B3
E9XTxB3H
3 Cr1 Mo
No matching
>>>
5 Cr1/2 Mo
E502 1X
ER502
E801X B6
ER 80X B6 E6XT5B6
E502T
E801X B6L
7 Cr1/2mO
E801XB7
No matching >>>
F9XX EXXX B6
F9XX EXXX B6H
9 Cr 1Mo
E5051X
ER505
E 8018 B8
ER 80X B8
EX15B8
E8018 B8L
9 Cr1 Mo Nb V
E 901X B9
E6XT5B8L
ER 90X B9
FXX EXXX B9
Under 4% Cr
Not required
4- 6% Cr - Preferable
> 6 % Cr - Essential
Partially welded pipes Care during handling to
avoid bending stress
PWHT temp
Steel
Temp ( C)
Cr-1/2Mo
620-704
1Cr-1/2Mo
620-720
11/4Cr-1/2 Mo
2Cr -1/2Mo
21/4Cr-1Mo
3 Cr1 Mo
680-760
5Cr-1/2 Mo
7 Cr1/2 Mo
700-760
9Cr-1Mo
9C1Mo V NbN
730-760
WELDING of 12 Cr steels
THICKENSS RANGE: 15 TO 75 mm
PREHEAT (ROOT) 250C
SUBSEQUENT PASS PREHEAT: 350C
ROOT RUN: TIG WELDING
FILLER PASS : MMAW
ELECTRODE BAKING: 300TO 350C
ELECTRODE HOLDING : 100 TO 150C( KEEP AT PORTABLE
OVEN)
Hold at 100C until taken for PWHT
HT 760 +- 10C 3min/mm
Slow cool after 300C
Temper embrittlement
Brittleness that results near ambient temp when
certain alloy steels are held in temp range 700 1100
F or cooled slowly in the range
Increase in ductile brittle transition temp
No change in tensile properties
Embrittlement is reversible
By heating above above 1100 F, can be de-embrittled
Occurs only in the presence of specific impurity
elements P, Sb,Sn As
Impurity build up by segregation at Grain boundary
Grain boundary decohesion takes place
1h
15h
1
24h
1
1- cooling rate 10 F / h
2 cooling rate 20 F / h
Transition temp for 40 ft lb(
60h
1
100h
1
AC
SMAW basic
3-9
120
250
SMAW Rutile
30-45
Cellulose
50-65
SAW
3-13
60
200-700
Self shielded
3-9
50 / 170 *
130
* Combined nitrogen
Heat Exchangers
TEMA
Structures
AWS D1.1
Tankage