1

PREDICTING WELD STRUCTURE

USING MODIFIED SCHAEFFLER CONSTITUTION DIAGRAM
V. Mazurovsky
1
, M.Zinigrad
2
, A. Zinigrad
3
Abstract
A mathematical model providing for predicting weld structure based on modified Schaeffler
diagram has been developed. The objective and the scope of diagram modification are
described.
Introduction
Schaeffler diagram is an important tool to predict Cr-Ni austenite, austenite-ferrite or
austenite-martensite weld with carbon content of up to 0.12%. However, it does not allow for
determining the composition and volume of carbide phase. Furthermore, if carbon content in
weld is over 0.12% (like, for example, in the case of hardfacing), the forecast agreement with
actual data is markedly reduced due to an intense consumption of carbon and carbide-
forming elements by the process of carbide formation. In addition, an accurate prediction can
be complicated either by a lower content (or absence) of Cr and Ni in the weld, or by a
higher content of Mn (above 4%). Firstly, it could be attributed to the fact that the carbide
formation process in weld is not taken into consideration (as mentioned above), and
secondly, it is caused by using constant empiric coefficients in the equations determining Cr
and Ni equivalents (Ref.1). The third problem relating to microstructure prediction based on
the Schaeffler diagram lies in the difficulty of determining the volume of a specific phase in
multiphase zones. Therefore, the Schaeffler diagram should be modified to provide a more
accurate prediction of weld structure as follows:
- taking into consideration of the carbide formation process;
- implementation of variable coefficients in Cr and Ni equivalents equations (the
coefficients should depend on the concentration and mutual influence of alloying
components, and on the carbide formation process in the weld);
- incorporating of phase percentage lines for interphase zones (i.e., the zones which
contain two or more phases, as performed by Schaeffler for austentite-ferrite zone).
It should be mentioned that various attempts were undertaken in order to improve the
efficiency and accuracy of the metal structure prediction based on constitution diagram. As
far as we know, no one of them provided a comprehensive solution for the above problems.
For instance, relatively new WRC-1992 Diagram and its modified versions (Ref. 2,3) do not
allow for predicting micro-structure of metals other than austenite-ferrite ones with carbon
content not higher than 0.12%. On the other hand, those researchers who proposed to modify
the Schaeffler Diagram (for example, Ref. 4) did not take into account the above-mentioned
problems, e.g. carbide formation.
1
CWC Ltd., Ariel, Israel
2
College of Judea and Samaria, Ariel, Israel
3
CWC Ltd., Ariel, Israel
2
Carbide formation process
As mentioned above, if carbon concentration is over 0.12%, the volume of carbon and
carbide-forming elements consumed for carbide formation can markedly increase. This
process is disregarded in the Schaeffler diagram. The authors believe that it could be a reason
for the disagreement between the matrix microstructure prediction results based on the
Schaeffler diagram and the actual data for steels with high carbon content.
To pay a due regard to the carbide formation process, the authors use a new notion of
carbide-forming ability of an element (CFA). It can be described by the following equation:
i
i
a
d
R
i
(1)

a
- absolute CFA of i-th element;
i
R - atomic radius of i-th element, ;
i
d - number of d-electrons at the outermost electron shell of i-th element.
Analysis of this equation (1) shows that CFA grows according to the following sequence:
Fe, Mn, Cr, Mo, W, Nb, V, Ta, Ti, Zr, Hf. However, in real alloys, CFA of a specific
element depends on its concentration and some other factors. Therefore, for practical
purposes, CFA of an element can be expressed as:
i
i
i r
d
R
i
(2)
i
r
- actual CFA of i-th element;

- coefficient which takes into account the above factors.

Determination of

coefficient is the most complicated challenge. The authors developed
an appropriate method, which allows them to determine

. The method cannot be published
at the present stage.
The quantity of carbon required to form carbides from the carbide-forming i-th element will
be as follows, %wt:
i i
r c
% C C (3)
% - carbon concentration in weld, % wt.
The quantity of carbon dissolved in the matrix is as follows, % wt:
3
_

n
1 i
c m
i
C % C C (4)
n - a number of carbide-forming elements in weld.
The quantity of i-th element consumed to form
j x g
) C Me ( -type j-th carbide:
c
i
c j i
xA
gA
C W E
i
j
)
x
C
g
Me (
(5)
j
W - probability of formation of j-th carbide;
g, x - stoichiometric coefficients in the j-th carbide chemical formula;
i
A - atomic weight of a carbide-forming i-th element;
c
A - atomic weight of carbon.
The total quantity of i-th element consumed to form carbides, % wt:
_

k
1 j
i c
j
)
x
C
g
Me ( i
E E (6)
k - the number of types of the carbides formed from a carbide-forming i-th element.
Now we can determine the quantity of the carbide-forming element dissolved in the matrix.
i i
c i m
E E E (7)
Therefore, the
m
C and
i
m
E values obtained while taking into account the carbide formation
process can be used to determine Cr and Ni equivalents.
At the same time, now we are able to calculate the amount of matrix-strengthening carbide
phases. The amount of carbide phase formed by i-th element is determined by the following
formula:
i i i
c c c
E C Q + (8)
i
c
Q - amount of carbide phase formed by i-th element, %wt;
i
c
C and
i
c
E - see (3) and (6) accordingly.
The total amount of carbide phase in weld will be as follows:
_

+
n
1 i
c c c
) E C ( Q
i i
(9)
4
At the same time, we must take into account the consumption of alloying elements to boride
and nitride formation. If Ni content in alloys is over 5%, the phase formation shall also be
taken into account. However, these issues cannot be described in the framework of this
paper.
Adjustment of coefficients in Cr and Ni equivalent equations
By analyzing the structures of more than 50 types of deposit weld metal, the authors
determined coefficient variation empirical dependencies for the equations defining Cr (
eq
Cr )
and Ni (
eq
Ni ) equivalents in the Schaeffler diagram (Ref.1). When modified, these
equations are as follows:
_

)
l
1 i
) Frt ( m i eq
i
E ( f Cr (10)
i
) Ast ( m
z
1 i
i eq
E Ni
_

) ( (11)
l - number of ferrite-forming elements;
i
) Frt ( m
E - concentration of ferrite-forming i-th element in the matrix, %wt;
) ( f
i
- function determining empirical coefficient for ferrite-forming i-th element;
z - number of austentite-forming elements;
i
) Ast ( m
E - concentration of austentite-forming i-th element in the matrix, %wt;
)

( - function determining empirical ratio for austentite-forming i-th element;

, - complex factors defined for the ferrite- and austentite-forming elements
based on the structure analysis, as described above.
Phase proportions in multi-phase zone of the Schaeffler diagram
Phase proportions in multi-phase zone of the Schaeffler diagram were found by means of the
structure analysis applied to determine the coefficients in equations (10), (11), and taking
into account carbide formation process (9). Accordingly, percentage lines for the amount of
the second (third) phase were incorporated in the appropriate zones of the diagram. For
three-phase zones, algorithms to determine each phase content were developed. The
modified Schaeffler diagram is shown in Fig. 1. The boundaries of austentite-martensite and
5
ferrite-martensite (perlite) zones are slightly displaced upwards, as confirmed by numerous
calculations and the analysis described.
Fig 1. Modified Schaeffler diagram taking into consideration the effect of carbide formation.
Computer implementation of the model
Equations (1) - (11) and the mathematical description of the Schaeffler diagram served as a
base of the mathematical model developed by the authors. The model is being implemented
for solving two tasks, namely:
a) direct task, i.e., microstructure forecast according to the chemical composition
of the weld;
b) reverse task, i.e., determination of the chemical composition of weld
according to the microstructure required.
The reverse task is of course the most complicated challenge.
Currently, a pilot version of software based on the above mathematical model has been
developed.
6
Model approbation
The above-mentioned software was approved by determining over 50 compositions of welds
with a known matrix composition (microstructure) and strengthening phase volume. The
obtained data proved a good agreement with the experimental data. The deviation did not
exceed 15-20%.
Conclusions
The Schaeffler diagram was modified as follows:
) consumption of elements to carbide formation was taken into account;
b) functional dependencies were applied to determine empirical coefficients in Nieq and
Creq equations;
) phase proportions in multiphase zones of the diagram were found.
The mathematical equations derived were used as a basis of a mathematical model to
determine the microstructure of weld and strengthening phases. Computer implementation
and approbation of the mathematical model were performed. The obtained results proved a
good agreement between the calculated and actual data.
References
1. Schaeffler, A.L. 1949. Constitution diagram for stainless steel weld metal. Metal Progress
56(11):680 - 680B.
2. Kotecki, D.J., and Siewert, T.A. 1992. WRC-1992 constitution diagram for stainless steel
weld metals: a modification of the WRC diagram. Welding Journal 71 (5): 171-s to 178-s.
3. Kotecki, D.J. 2000. Forecasting weld microstructure. Advanced materials and processes,
157 (6): 74 77.
4. Beres, L. 1998. Proposed modification to Schaeffler diagram for chrome equivalents and
carbon for more accurate prediction of martensite content. Welding Journal, 77 (7): 273-s to
276-s
5. Olson, D.L. 1985. Prediction of austenitic weld metal micristructure and properties.
Welding Journal 64 (10): 281-s to 295-s