Materials Science and Engineering A364 (2004) 244248

Numerical simulation on residual stress distribution of hard-face-welded steel specimens with martensite transformation
Qing Xiang Yang a, , Mei Yao a , Joongkeun Park b
b a College of Materials Science and Engineering, Yanshan University, Qinhuangdao, Hebei 066004, PR China Department of Materials Science and Engineering, Korea Advanced Institute of Science and Technology, Taejon 305-701, South Korea

Received 13 February 2003; received in revised form 8 August 2003

Abstract FEM models are established for calculations of the temperature elds during cooling and the internal stress eld of a mediumhigh carbon steel specimen after hard-face-welding (hardfacing) by using an electrode with lower carbon content. The martensite transformations in both welded metal and matrix are considered in the model for calculation of the internal stress eld. The validity of these models was veried by the experimental results of temperature eld, as well as the residual (internal) stress eld, determined at the surface of the specimen. Based on the calculated results, the effect of martensite transformation points on the residual stress elds is analyzed. 2003 Elsevier B.V. All rights reserved.
Keywords: Numerical simulation; Residual stress; Hard-facing metal; Martensitic transformation; Mediumhigh carbon steel

1. Introduction Hard-face-welding (hardfacing) is a technique widely used for the repairing of damaged metal parts made of mediumhigh/high carbon steels, such as mill rollers, tools and dies [13]. These steels, as well as the hardfaced metal, normally have carbon content higher than 0.50% and contain Cr, Mo, V and other alloying elements. After hardfacing, in the welding metal and the heat-affected zone (HAZ) of specimen, there often occurs martensite with high hardness, which is quite sensitive to formation of cold crack. The most effective technological measures for prevention of crack formation are the pre-heating and the afterward re-heat-treatments, which, however, are quite inconvenient or even impossible in some cases. Then, it is of great signicance to investigate new kinds of electrode, by using that, the hardfacing can be carried out without or with low temperature pre-heating, as well as without or with simple afterward heat-treatments. The formation of cold cracks during welding is in general a function of three main factors that are the formation of martensite with high hardness, the existence of hydrogen
Corresponding author. Tel.: +86-335-805-5593; fax: +86-335-805-7075. E-mail address: qxysyfys@yahoo.com (Q.X. Yang). 0921-5093/$ see front matter 2003 Elsevier B.V. All rights reserved. doi:10.1016/j.msea.2003.08.024

and the occurrence of tensile residual stress [4]. The existence of hydrogen can be limited by baking the electrodes. The sensitivity of martensite to crack formation is mainly dependent on its carbon content, which will not be changed in matrix metal during welding, but, in welding metal, it can be controlled by adjusting the chemical compositions of used electrode [5]. Nevertheless, the carbon content in welding metal should be kept on a needed level to guarantee the wear resistance of the hardfacing layer. Another factor inuencing the crack formation is the occurrence of tensile residual stress after welding [6]. The residual stress at room temperature after welding is the retained internal stress, which occurs due to the non-simultaneity of temperature change and phase transformation at different sites of specimen during cooling. Upon cooling after hardfacing, the metal is shrunk due to the temperature lowering; while, austenite is slightly denser than martensite, and therefore, during the phase transformation, there is a net volume increase. Then, the formation of the internal stress, as well as the residual stress, should be able to be adjusted by adjusting the martensite transformation in the welding metal, which is dependent mainly to the chemical compositions of welding metal. The direct measurement of temperature during cooling is quite difcult and the direct measurement of internal stress is simply impossible, so the investigation of the temperature elds, as well as the internal/residual stress

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elds during hardfacing is a complex problem and has not been deeply studied. Recently, some attempts are carried out to calculate the temperature and the internal stress elds by FEM [79], which should be an effective technique to resolve above-mentioned problem. In this paper, a numerical simulation to calculate the internal and residual stress distributions on simplied hardfacing specimens is carried out and the calculated results are veried by some experimental data; and then, the effect of martensite transformation is discussed. The results of this paper are important for the chemical composition design of new types of hardfacing electrode, which can be used under simplied pre-heating and afterward heat-treatment procedures.

Table 2 Parameters for residual stress determining by X-ray method Parameters name Target material Tube volume (kV) Tube current (mA) Diffraction crystal plane 2 scanning angle Numbering time (s) Stress parameter (MPa per degree) Stress determining method Parameter CrKa 25 5 (211) 0.1 1 318 Fixing

method

2. Experimental and calculation procedures Specimens used for testing and calculations were made of hot roller steel 60CrMnMo with chemical compositions given in Table 1. The dimensions of specimens are 90 mm 90 mm 24 mm. A small hole with diameter of 22 mm and depth of 2 mm was machined in the center of the upper face of the specimens. A commercial electrode marked D397 and a specially designed cracking-resistant electrode adding RE (rare earth) and Ni were adopted to ll the small hole by using arc-welding technology. The chemical compositions of the hardfacing metals by using different electrodes are determined beforehand and are also given in Table 1. The hardfacing were carried out with electric current of 100 A. In all cases, the operating time is 16 s. After the operation, the temperature elds around the welding point during cooling process were measured at given moments by using an infrared thermo-vision analyzer of type 780. After cooling to the room temperature, it has been found that at the specimen, hardfaced by using electrode D397, both the hot cracks (in the middle region of the hardfacing metal) and the cold cracks (near the boundary of the hardfacing metal and the HAZ of matrix metal) were observed [10], while at the specimen hardfaced by using cracking-resistant electrode, no cracking has been detected [11]. For specimens with cracks, there is nonsense to study the residual stress eld, then the determination of residual stress only carried out on the specimen hardfaced by using the cracking-resistant electrode. The residual stress eld was determined by an X-ray residual stress analyzer of type AST 2001 and the parameters for determining the residual stress are listed in Table 2. The experimental data of temperature and residual stress elds

Fig. 1. Mesh division.

were used to verify the calculated results. The numerical simulations of temperature and internal stress elds are carried out by using a commercial software ANSYS for FEM calculation. Because of little effect of temperature on the sides of specimen, the square specimen can be simplied to the disc one with diameter equal to the side length of square specimen. In this case, the temperature and internal stress elds can be treated as the axial symmetry ones. The FEM mesh division is given in Fig. 1 (241 elements are divided and 263 nodes are formed), in which the hardfacing region is shown by dotted lines. During calculation, some thermo-physical and mechanical parameters were supposed as constant: the density, = 7.85106 kg/mm3 ; the elastic modulus, E = 2105 MPa and the Poissons ratio, = 0.3. Other parameters [1216] are given in Table 3, in which, the exchanging coefcient () is calculated by following equation [17]:
2 = 2.2(Tw Tc )0.25 + 4.6 108 (Tw + Tc2 )(Tw + Tc )

(1)

Table 1 Chemical compositions of matrix steel and hardfacing metal (wt.%) Materials 60CrMnMo Hard-facing metal when the electrode D397 is used Hard-facing metal when the cracking-resistant electrode is used C 0.64 0.57 0.54 Cr 1.04 1.95 1.80 Mn 1.88 2.36 1.10 Mo 0.22 0.66 0.52 Ni 1.70 Si 0.33 0.54 0.64 S 0.038 0.035 0.032 P 0.016 0.04 0.03 RE 0.085

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Table 3 Thermo-physical and mechanical parameters of 60CrMnMo steel used for FEM calculation [1216] Parameter Temperature ( C) 200 Thermal conduction coefcient () Average heat capacity (c) (103 J/kg C) Specic enthalpy (H) (103 J/kg) Exchanging coefcient () (106 W/mm2 C) (103 W/mm C) 41.9 0.502 100 18.85 400 39.4 0.536 214 33.44 600 32.3 0.586 352 55.95 800 29.1 0.695 557 88.92 1000 26.5 0.674 674 134.6 1200 29.4 0.670 804 195.4 1400 29.4 0.670 804 273.4 1600 29.4 0.670 804 370.9

Fig. 2. Region division for internal stress eld calculation. A1, hardfacing metal; A2, HAZ; A3, matrix steel 60CrMnMo.

where Tw is temperature of specimen and Tc is that of environment. During calculation of internal stress eld, the martensite transformations in specimen were taken into account. Based on the features of phase transformation, the whole specimen can be divided into three regions: the hardfacing metal region (A1), in which the martensite transformation occurs at higher temperature; the HAZ (A2) near the hardfacing metal with pick temperature higher than AC3 , in which the martensite transformation occurs at lower temperature and the zone of matrix (A3) far from hardfacing metal with temperature lower than AC3 , in which the martensite transformation dose not occur. During calculations of internal stress eld, the different features of these three regions should be considered comprehensively. According to the calculated results of temperature eld, the dimensions of heat-affected zone can be determined. A simplied division of these three regions is shown in Fig. 2. The martensite transformation temperatures Ms and Mf of matrix steel 60CrMnMo, as well as those of hardfacing metals, were determined by using tangent method from

the dilatometric curves obtained on a high speed automatic dilatometer of type Formaster-D and are given in Table 4. It can be seen, the heating temperature has little effect on the martensite temperatures, especially higher than 1000 C. In this work, the martensite temperatures determined after heating at 1000 C were used for internal stress eld calculation. The expansion coefcients needed for calculations can also be obtained based on the dilatometric curves and are listed in Table 5. The internal stress eld induced during cooling after hardfacing is also related to the yield strengths ( s ) of the matrix and hardfacing metal. It is assumed [17] that the steel becomes ideal-plastic ( s gets to zero) when the temperature is higher than 600 C. When the temperature is lower than that, the s increases with the decrease of temperature. In regions A1 and A2, when the austenitemartensite phase transformation occurs, the yield strength will be changed sharply and increase with the transformed amount of martensite. The values of yield strength of these three regions used for calculations of internal stress elds are given in Table 6.

3. Results and analyses 3.1. Temperature elds Comparisons between measured and calculated results of temperature elds on the surface of hardfaced specimen are shown in Fig. 3. Fig. 3(a) shows the temperature elds of hardfacing metal at t = 18 and 35 s (2 and 19 s after welding operation) and Fig. 3(b) shows the temperature history at r = 0 (the center of hardfacing metal) and r = 14 mm (HAZ). It can be seen, that there are little differences between the measured and the calculated results. This fact indicates that the model used for temperature eld calculations is correct and obtained results can be used for further calculation of internal stress eld of specimens after hardfacing.

Table 4 Martensite transformation temperatures of different materials Materials ( C) T Ms Mf Steel 60CrMnMo 800 230 135 1000 225 130 1200 215 125 Hard-facing metal welded by using electrode 800 348 232 1000 345 225 1200 338 225 Hard-facing metal welded by high cracking resistance with RE and Ni 800 330 228 1000 325 223 1200 322 160

Q.X. Yang et al. / Materials Science and Engineering A364 (2004) 244248 Table 5 Expansion coefcient used for the calculation of internal stress eld (106 / C) T ( C) A1 region T ( C) A2 region T ( C) A3 region 50 10.5 50 10.5 50 10.5 100 11.8 125 11.8 100 11.8
1600 calculated t = 18s 1200 T, 0C calculated t = 35s measured t = 18s measured t = 35s 800 1200 T, 0C 1600 calculated r = 0mm calculated r = 14mm measured r = 0mm measured r = 14mm 800 400

247

150 12.9 130 11.7 150 12.9

220 13.9 200 11.7 200 13.9

225 11.7 225 11.7 250 14.7

300 11.7 230 14.7 300 15.4

325 11.7 300 15.4 350 15.9

330 15.9 350 15.9 400 16.2

550 16.5 500 16.5 550 16.5

600 16.7 600 16.7 600 16.7

650 16.7 650 16.7 650 16.7

1600 16.7 1600 16.7 1600 16.7

400

(a)

10 15 20 25 30 35 40 45 r, mm

20

40

60

(b)

80 100 120 140 160 t, s

Fig. 3. Comparison of measured and calculated results of temperature elds on the surface of specimen. (a) Temperature elds of hardfacing metal at t = 18 and 35 s (2 and 19 s after welding operation). (b) Temperature history at r = 0 (the center of hardfacing metal) and r = 14 mm (HAZ). Table 6 Yield strength ( s ) used for the calculation of internal stress eld (MPa) [17] T ( C) A1 region T ( C) A2 region T ( C) A3 region 100 2400 100 2400 100 1200 225 2400 130 2400 300 800 325 400 225 400 550 650 550 400 550 400 600 20 600 0 600 0 1000 0 1600 0 1600 0 1600 0

on tendency. There are two peaks of tensile residual stress appeared. One is located in the center of hardfacing metal, and another is in the HAZ near the hardfacing metal. These are just the positions where the cracks being often observed. Then, this procedure can be used for further modeling-calculation of residual stress elds with different features of martensite transformation of hardfacing metal. 3.3. Effect of martensite temperatures of hardfacing metal on residual stress elds The change of martensite transformation temperatures will cause the change of the residual stress distribution. As shown in Table 4, the martensite transformation temperature Ms of hardfacing metal welded by using electrode D397 is 345 C, while, by using cracking-resistant hardfacing electrode with addition of Ni and RE elements, it is 325 C. The
800 700 600 500 400 300 200 100 0 -100 -200

3.2. Residual (internal) stress elds The calculated residual stress distribution and measured data on the surface of specimen after hardfacing are shown in Fig. 4. It can be seen, that the calculated results of the residual elds is in accordance with the measured ones
800 600 Stress, MPa 400 200 0 -200 -400 0 5 10 15 20 25 30 35 40 45 r, mm Calculated Measured

Calculated Measured

Stress ,MPa

(a)

(b)

10 15 20 25 30 35 40 45 r, mm

Fig. 4. Comparison of measured and calculated results of residual stress distribution. (a) Radial stress and (b) tangential stress.

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1100 800 700 600 500 400 300 200 100 0 -100 -200 0
Ms = 345 C Ms = 335 C Ms = 325 C Ms = 315 C

900 700 Stress,MPa 500 300 100 -100

Stress,MPa

Ms = 345 C Ms = 335 C Ms = 325 C Ms = 315 C

t = 180s

(a)

5 10 15 20 25 30 35 40 45 r,mm

-300 0

(b)

5 10 15 20 25 30 35 40 45 r,mm

Fig. 5. Residual stress elds on the surface of specimen with different Ms temperatures of welding metal. (a) Radial stress and (b) tangential stress.

residual stress eld calculations by using these data, as well as other two values of Ms , 335 and 315 C, have been carried out and are given in Fig. 5. It can be seen, with the lowering of Ms of hardfacing metal, the peak values of tensile residual stress at dangerous positions reduce. When Ms is equal to 315 C, the residual tensile stress in the center of hardfacing metal even becomes compressive, which is considered to be benet to avoid the occurrence of cracks. This fact should be another important reason for the different cracking behaviors of specimens welded by using electrode D397 and cracking-resistant electrode and should be taken into account during the chemical composition design of the electrode. 4. Conclusions 1. The calculated results of temperature and residual stress eld of hardfaced specimen are in accordance with the experimental data, which proves that the proposed procedures are correct. 2. Two peak values of tensile residual stress appear on the surface of the specimen. One is located in the center of hardfacing metal and another is located in the HAZ near hardfacing metal. 3. With the lowering of the martensite transformation temperature Ms , the peak values of tensile residual stress at dangerous positions reduce, which is considered to be benet to avoid the occurrence of cold cracks.

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