Module 8

Module 8
Welding Metallurgy
for the Welding
Inspector
Cairo Inspection Company
Eng. Ibrahim Eldesoky
ASNT NDT-LEVEL III
ASME AUTHORIZED INSPECTOR
Metallurgy
The science dealing with the
internal structure of metals
and metal properties
Cairo Inspection Company (CIC)
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Welding Metallurgy
Concerned with the changes
occurring in metals during
welding
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Discussion Topics
Structures
Changes on heating
Changes on cooling
Heat treatments
Alloying
Phases
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Atomic Structure
Matter made up of atoms
Atoms are very small
Electrons orbit atomic nuclei
Have a home location in solids
Oscillate around home position
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Atomic Structure Simple Cubic
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Home Location
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Solids
Minimum internal energy
Atoms fixed in place
Atoms have home position
Atoms vibrating
Orbiting electrons
Crystalline structure
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Liquids
Higher internal energy
Atoms free to move
Atoms vibrating more
Orbiting electrons
No fixed structure
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Solid vs Liquid
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10
Thermal expansion
on Heating
Thermal contraction
on Cooling
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11
Welding Stresses (Tensile)

Remain after welding is completed (residual
stress)
Can cause distortion
(welding stress exceeds yield strength of
material)
Can cause cracking
(welding stress exceeds tensile strength
of material)
Residual stress can be as high as yield
strength
Relieved by three methods
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12
Stress Relieving
Thermally
Vibratory
Peening
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Crystal Structures
BCC - Body Centered Cubic
FCC - Face Centered Cubic
HCP - Hexagonal Close Packed
BCT - Body Centered
Tetragonal
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Common
Crystal
Structures
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Metal
Solidification
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Grain Size Effects

Fine grained materials
Have good tensile strength
Have good ductility
Have good low temperature
properties
Coarse grained materials
Have slightly lower strength
Are slightly less ductile
Have good high temperature
properties
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17
Alloying
Adding elements to change
mechanical or physical
properties
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18
Interstitial
Alloying
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19
Interstitial Alloying Results in Lattice Distortion
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20
Substitutio
nal Alloying
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21
Substitutional Alloying Results in Lattice Distortion
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22
Microstructures
Metals composed of grains
(crystals)
Very small
Separated by grain boundaries
Different phases within grains
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23
Microstructure
of Iron
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24
Iron-Carbon
Phase Diagram
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25
Phases in Steel
Ferrite
Cementite
Austenite
Bainite
Pearlite
Martensite
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26
Cooling Rates
Slow
Moderate
Fast
- Pearlite
- Bainite
- Martensite
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- softest
- hardest
27
Lamellar Appearance of
Pearlite
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Martensite
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29
Tempering
Restores ductility and
toughness and reduces strength
and hardness
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Effects of Tempering
Temperatures
Alloy is AISI 4142
Tempering
temperature is in
degrees F
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Effects of Tempering
Temperatures
Alloy contains 12% Cr
Note reduction in
impact strength at
885 F (475 C)
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32
Continuous Cooling
Diagram & Jominy
Hardenability
Diagram for 8630
steel. Phase formed
on cooling varies
with cooling rate.
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33
Weld Area & Fe - Fe3C Diagram
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34
Heat Input
Joules/inch = current x voltage x 60
travel speed (in./min)
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35
Preheat
Slows cooling rate
Produces less martensite
Reduces risk of cracking
Reduces distortion
Reduces hydrogen
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36
Carbon Equivalent
( CE )
CE = % C + % Mn + % Ni + % Cr + % Cu + % Mo
6
15
5
13
4
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37
Examples of
Preheating vs C.E.
C.E.
< 0.45
0.45 - 0.60
>0.60
Preheat Temperature
Optional
2000 - 4000 F
4000 - 7000 F
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38
Heat Treatments for

Steels
Super-critical - above
transformation temp.
Annealing
Normalizing
Quenching (to harden)
Sub-critical - below transformation
temp.
Tempering
Stress Relieving
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39
Diffusion
Movement of atoms within a
solution, be it a solid, liquid or gas
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Diffusion of Lead and

Gold Atoms
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41
Solubility
Dissolving Salt into
Water
Solid into liquid
Diffusion mechanism
Solubility limit
Temperature effects
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42
Solid Solubility
Unique to metals
Solid into solid
Solubility limit
Temperature effects
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43
Examples of Solid
Solubility
Gold and lead bars
Carburizing
Nitriding
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44
Stainless Steels
Ferritic
Martensitic
Austenitic
Precipitation Hardening (PH)
Duplex
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45
Sensitization of
Austenitic Alloys
Formation of chromium carbides
between 800 - 1600 degrees F
(Sensitization reduces the
corrosion resistance in many
environments)
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46
Corrosion Attack of Austenitic

Stainless Steel
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47
Avoiding Sensitization
Heat treatment ( SAWQ )
Stabilized grades
Low carbon grades
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48
Other Common Alloys

Aluminum
Pure aluminum
Aluminum-copper
Aluminum-magnesium
Copper
Pure copper
Brasses
Bronzes
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49
Main Content Page Layout
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The End any questions?
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51

Module 8

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Module 8

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Atomic Structure Simple Cubic

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Welding Stresses (Tensile)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Grain Size Effects

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Interstitial Alloying Results in Lattice Distortion

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Substitutional Alloying Results in Lattice Distortion

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)

Eng. Ibrahim Eldesoky

Cairo Inspection Company (CIC)