WELD SAMPLE LAB

MFET 3750
KELBY SAYER

INTRODUCTION
It should now be understood how carbon affects the mechanical properties of steel. As a quick
review, higher amounts of carbon can increase hardness, which will result in high tensile
strengths. Too much carbon can also create brittleness, so there is a fine line of too much and just
enough carbon to achieve the best mechanical properties in steel. Likewise, grain structure size
can have a great impact on steels performance. A finer grain structure will be more durable than a
coarse grain structure. Coarse grain structures can fracture easier since their grain boundaries are
straighter for longer distances than that of a fine grain structure.
This lab examined the microstructure change in 4140 steel as it was welded. 4140 is a chrome
moly steel that is 0.38-0.43% carbon, 0.50-0.95% chromium and 0.12-0.30% molybdenum. . The
properties of the filler metal in this lab should be examined as well. An ER70S-6 filler metal was
used and contains roughly 0.09% carbon, 0.05% chromium and 0.05% molybdenum. To better
understand how 4140s hardness is achieved, its composition and alloying elements should be
further examined. Chromium, when added to steel, increases its corrosion resistance,
hardenability and wear resistance. Molybdenum will deepen the hardening, raise creep strength
and hot-hardness, enhance corrosion resistance and increase wear resistance
Knowing that carbon relates to hardness, it can be predicted that chromium and molybdenum
assist carbons existence in steel at a high percentage. Also, knowing that molybdenum increases
hot-hardness, it can be observed that the steel will want to resist the change in its crystalline
structure when it is heated up by welding. A pre-heat of 200 F was applied to the specimen in
this lab to lower this resistance as it was welded.
It can be predicted that the specimens grain structure, when viewed through the microscope, will
be segregated at the fusion zone into a high concentration of pearlite to a lower concentration of
pearlite due to the composition of the base metal versus the filler metal. Also, the heat affected
zone will gradually move from a fine grain structure in the base metal to a coarser grain structure
as the proximity of the welded area gets closer.

OBJECTIVE
This lab identified the difference in grain structure between the base metal and the weld metal
via microscope. While viewing the specimen through the microscope, changes in the fusion zone
and heat affected zone were observed. The difference in concentration levels of pearlite in the

base metal and different layers of weld were apparent under the microscope as well, showing
how the carbon blended into each layer.
MATERIALS

AISI 4140 .75x 4.00

Welding equipment, electrode
Welding hood, welding gloves, welding protective wear
PSE-safety glasses

PROCEDURE
First, the specimen was pre-heated to 200F. Three layers of weld metal were deposited onto the
specimen via GMAW, with each pass traveling in the same direction. The specimen was allowed
to slowly air cool to room temperature. The specimen had 1.00 removed from its length by a
metallurgical saw. The 1.00 piece of the specimen was polished and etched. Once a correct
amount of etching was obtained, the specimen was viewed under a microscope and its
microstructure was evaluated.

RESULTS
Figure 1 shows how the grain structure immediately changed at the fusion zone. It is observed
that the grain size is larger in the weld metal than it is in the base metal and the pearlite grouped
together to make larger grains that were more spread out from each other. The difference in grain
size is also observed in Figure 2-5 as the images move from the base metal to the outermost
weld.

Figure 2 800x magnification of base metal.

Figure 3 800x magnification of first pass weld

metal.
Figure 1 600x magnification of fusion zone.

Figure 4 800x magnification of second pass

weld metal.

Figure 5 800x magnification of cover pass weld

metal.

While the grain structures growth is apparent from weld to weld in these images, the growth
from the heat affected zone can be observed also. Figures 6, when compared with Figure 2,
shows how the grain size grew in the base metal due to being within the heat affected zone.

INTERPRETATION OF RESULTS

Figure 6 800x magnification of fusion zone and heat

affected zone.

From the results, it is observed that the mechanical properties in 4140 steel are altered by the
heat of welding. It is apparent that a rapid change in the microstructure occurs at the point of
fusion with the welding metal. Though the composition of the filler metal is different than that of
the 4140, heat alone can alter the microstructure as observed in the heat affected zone.
CONCLUSIONS
This lab demonstrates how much consideration of mechanical properties of steel should be taken
into account when certain metals are put through the welding process. If the welding process
doesnt incorporate the correct pre-heating procedures, the hardness and strength of the metal can
be compromised due to rapid changes in the microstructure at fusion and heat affected zones. If
the application of the steel is dependent upon the steels performance before welding, thorough
testing and evaluation should take place followed by a well written procedure.