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Weld metal
Fusion line
Base metal HAZ
Hot crack in a restrained fillet weld bead on left of vertical member was deposited after the one on the right
Hot crack developed in the left bead because of greater degree of restraint
METALLOGRAPHY
In filler weld cracks in the HAZ are usually associated
with the weld root & parallel to the weld in butt welds
The HAZ cracks are normally parallel to the weld beads.
Causes
There are three factors which combine to cause cracking:
Cracking is caused by the diffusion of hydrogen to the highly stressed, hardened part of the weldment.
In C-Mn steels, because there is a greater risk of forming a brittle microstructure in the HAZ, most of the
hydrogen cracks are to be found in the parent metal. With the correct choice of electrodes, the weld metal
will have a lower carbon content than the parent metal and, hence, a lower carbon equivalent (CE).
However, transverse weld metal cracks can occur especially when welding thick section components.
In low alloy steels, as the weld metal structure is more susceptible than the HAZ, cracking may be found in
the weld bead.
The effects of specific factors on the risk of cracking are::
The higher the CE value, the greater the risk of hydrogen cracking. Generally, steels
with a CE value of <0.4 are not susceptible to HAZ hydrogen cracking as long as
low hydrogen welding consumables or processes are used.
Parent material thickness
Material thickness will influence the cooling rate and therefore the hardness level, microstructure produced
in the HAZ and the level of hydrogen retained in the weld.
The 'combined thickness' of the joint, ie the sum of the thicknesses of material meeting at the joint line, will
determine, together with the joint geometry, the cooling rate of the HAZ and its hardness. Consequently, as
shown in Fig. 3, a fillet weld will have a greater risk than a butt weld in the same material thickness.
Heat input
The heat input to the material from the welding process, together with the material thickness and preheat
temperature, will determine the thermal cycle and the resulting microstructure and hardness of both the
HAZ and weld metal.
Submerged arc
(single wire)
MMA
MIG/MAG and flux cored wire
TIG and plasma
1.0
0.8
0.8
0.6
In MMA welding, heat input is normally controlled by means of the run-out length from each electrode
which is proportional to the heat input. As the run-out length is the length of weld deposited from one
electrode, it will depend upon the welding technique eg weave width /dwell.
Hydrogen cracking may also be called cold cracking or delayed cracking. The principal distinguishing
feature of this type of crack is that it occurs in ferritic steels, most often immediately on welding or after a
short time after welding.
Preheating ,interpass &post heating , drying electrode , cleaning the joint from
oil , paint , . To prevent hydrogen cracking.
Preheat :
The recommended levels of preheat for carbon & carbon manganese steel detailed in the AWS D1.1
TABLE ( )
The preheat level may be as high as 200c when welding thick section steel with high CE value.
Interpass and post heating
In some cases preheating temperature to hold 2-3 hours to enable the hydrogen to diffuse away from the
weld area.
When CE high we heat to 250C - 300C FIR 3-4 HOURS to enable hydrogen to diffuse away.
<5ml/100g
Low
5 - 10ml/100g
Medium
10 - 15ml/100g
High
>15ml/100g
Figure 2 illustrates the relative amounts of weld metal hydrogen produced by the major welding processes.
MMA, in particular, has the potential to generate a wide range of hydrogen levels. Thus, to achieve the
lower values, it is essential that basic electrodes are used and they are baked in accordance with the
manufacturer's recommendations. For the MIG process, cleaner wires will be required to achieve very low
hydrogen levels.
Inspection &detection
Surface breaking hydrogen crack can be detected using
Visual examination , liquid penetrant or magnetic test
Internal cracks
Ultrasonic tests , radiographic test
Lamellar tearing
Occur specially when lack of through thickness ductility z direction
Causes
Transverse strain the shrinkage strains on welding must act through the plate
thickness
Weld orientation the fusion boundarywill be roughly parallel to the thickness
inclusions
Material susceptibility the plate must have poor ductility in the through thickness
direction
The risk of lamellar tearing will be greater if the stresses generated on the through
thickness direction
The risk will also increase the higher the level of hydrogen.