iraz08 Factors to Consider When Welding Dissimilar Strength Carbon and Low-Alloy Stels Categories: Feature Stories Date: Apr 27, 2610 Title: Factors to Consider When Welding Dissimilar Strength Carbon and Low-Alloy Steels In an ideal world, the materials that companies weld in the manufacturing, fabricating, construction and other such industries would all match perfectly-both in their mechanical and chemical composition. This scenario would certainly simplify the welding process, especially the selection of filler metals. Yet in many applications it is necessary to weld together materials that have differing strengths. Doing so allows companies to save money ‘on material costs and also to utilize materials that can better accommodate the end service conditions of the completed components. Attaining success when welding dissimilar strength steels, however, requires close attention to a few key factors, as well as proper filler metal selection. Factors to consider include: determining the weldability of the materials to be joined; assessing the service condition to whieh the parts will be subjected; and finally, considering the proper welding, preheat, and interpass temperature requirements for the application, Filler Metals: The General Rule In most cases, when welding dissimilar strength materials the tensile strength of the filler metal should be matched as closely as possible to the lower strength material. Doing so offers the least potential for cracking. For example, when welding A514-a 100ksi yield low alloy quench and tempered steel-to A36 steel with 36 ksi yield strength, the most appropriate filler metals would more closely match the strength of the A36 material. In this situation, filler metals with 70 ksi tensile (typically the lowest strength available in the market place) would be a suitable ‘match.’ Attaining success when welding dissimilar metals requires close attention to factors such as weldability, service conditions, ‘preheat and interpass temperature control requirements, ‘as well as proper filler metal selection, In some cases, undermatching the strength of the filler metal to the lower strength material may be appropriate if the joint design allows for it. For example, some fillet welds created when welding a 100 ksi yield, quench and tempered material like A514 to an even higher strength, proprietary HSLA 130 material can accommodate welds created by 70 ksi strength filler metals. In this situation, the joint design, despite the lower strength weld, will still provide adequate overall strength for the application. ‘Companies should always consult the welding specifications for their application to determine whether undermatching the filler metal is appropriate. Overmatching' filler metal strength when welding dissimilar strength materials is typically not recommended, as it can create too much stress in the lower strength side of the weldment and weld interface, causing potential failure typically at the toe of weld. ipuhwwrhobertorcthers.comindex pop?mact=News cin print erin arileié=S68crin0tshowlamplate=flseBcrintOteturide523 488016 Facts o Consider When Welding Dssiilor Strength Carbon and Low-Alloy Stas What is the Weldability? In addition to the general rules of filler metal matching, one of the first factors to consider when welding dissimilar strength materials is to determine the weldability of the two metals. Weldability refers to the general ability of two materials to be joined together successfully (e.g. without defects like cracking due to the material chemistry) and to obtain the mechanical properties necessary for the application, This factor varies from ‘material to material and often depends on other criteria such as the joint configuration and the service conditions that the final weldment will encounter. Part of determining weldability is calculating the carbon equivalency (CE) of the base materials. The typical CE Calculation Formula used in industries is as follows: CE=C+(Mn*Si/6(Cr'Mot VS#(Ni#Cuy/15. ‘The CE helps to determine cracking susceptibility, as well as the necessary preheat and interpass temperature control required during welding.A given material's weldability may be identified by ASTM, ASME, AISI, SAE or similar standards, all of which provide the chemistry requirements and/or mechanical property requirements for the base materials. As part of determining weldability, engineers, designers, and welder/welding operators need knowledge of the chemistry of the two dissimilar strength materials that are to be joined, as itis probable (but not absolute) that they will be comprised of varying chemical compositions. An example here would be welding ASTM AS72 Grade 50 to AISI/SAE 4140, in which the former material has both chemistry and ‘mechanical requirements, but the latter has only a chemistry requirement. tis important to determine the weldabilty of dissimilar strength materials prior to joining them together for a number of reasons. One, it helps establish how easily the materials can be welded together. It can also help determine which welding process and filler metal is most appropriate for the job. Further, it can help determine the suitability of the materials for the given application. For example, if the components that are being welded will be under a cyclic load, the two dissimilar strength materials and the deposited weld metal must be compatible for fatigue life. Most importantly, by determining the weldability of the materials, engineers, designers, and welders/welding operators can better ascertain their susceptibility to problems like hydrogen cracking and take the necessary precautions against them, Such precautions could include selecting low hydrogen filler metals and/or applying an appropriate preheat and interpass temperature controls and if required, post-weld heat treatment. A good reference source for weldability of steels is Weldability of Steels by Robert D. Stout and W. D'Orville Doty, WRC. What are the Service Conditions? ‘When welding dissimilar strength materials together it is critical to determine the service conditions to which the final component, and therefore, the weldment will be subjected. Considering these factors, of course, also contributes directly to the selection of a filler metal that can accommodate those service conditions, For example, it is not uncommon to weld dissimilar strength materials together to create components that will, in part, encounter high-temperature conditions. A company may want to attach ASTM A387 chrome-moly grade steel tubes for a high temperature, corrosion-resistant boiler application to a transition piece of A36 steel that will not encounter the same temperatures. In this situation, the chrome-moly may have a yield strength around (60 ksi and a tensile strength of 80 ksi; the A36 steel, as mentioned before, has a 36 ksi yield strength. Not only does a welder/welding operator need to select a filler metal that matches the lower strength material, but it may also need to find a filler metal capable of being stress relieved. High temperature applications (the chrome-moly portion) typically don't require the toughness brought forth by this process. In this example, the A36 steel attached to the chrome-moly steel, however, would require it to be post-weld heat treated. Welding dissimilar materials that are subject to highly abrasive service conditions also requires special attention. In many construction applications, companies protect their heavy equipment from day-to-day wear by welding abrasion-resistant (AR) plates to components such as bulldozer blades or backhoe buckets, Unfortunately, welding AR plate to a softer or lower strength steels (usually A36 or A572) brings with it the potential for cracking in the heat-affected zone (ITAZ) of the AR plate. Here, welding operators would need to use a joint design, such as a short, small fillet weld that can reduce heat input and overall residual stresses on the AR plate, pst hobertacohers.convindexkpmact=News crn print OScrinttariclid= SeréDshowlempate=alseScrintteturig=523, 23ir80%6 Facts o Consider When Welding Dssiilor Strength Carbon and Low-Alloy Stas and also find a filler metal that can resist cracking. As a rule, proper preheat and interpass temperature controls, and undermatched filler metals with low diffusible hydrogen levels offer the least amount of potential for cracking when higher strength and less ductile materials are welded to the lower strength material Of course, every welding application is different. As in these examples, however, considering the end service conditions, such as heat and abrasion, is crucial to determining what filler metals, joint designs and other factors can best accommodate the differences in material strengths ‘What are the Welding, Preheat, and Interpass Temperature Requirements? Paying close attention to welding requirements, including pre-heat and interpass temperatures requirements, as well as any post-weld treatments, if required, are key to the successful welding of dissimilar strength materials. ‘And in some cases, the preheat and interpass requirements may even call for a re-qualification of the welding procedure. For example, engineers, designers, and welders/welding operators may encounter an application in which the two dissimilar strength materials to be joined require differing pre-heat and interpass temperature controls, Consider a joint comprised of ASTM A514 steel that requires a 225 degree F pre-heat and AISI/SAE 4140 steel that requires 600 degree F pre-heat. Strictly speaking, following the more stringent of the requirements (in this case, the 600 degree F pre-heat) could prevent problems such as cracking; however, it may also affect the integrity of the A514 steel. Instead, it may be advisable to compromise between the two heating requirements- pethaps choosing a 350 degree F pre-heat. In critical applications, companies may need to re-qualify their ‘welding procedures to ensure that such a compromise still provides adequate strength and mechanical properties. Tn many cases, after welding, welds created on dissimilar strength materials can be used in the ‘as-welded’ condition, meaning the final weldment is acceptable for service after passing inspection. It does not require any type of post-weld heat treatment and matching the filler metal to the lower strength base metal will provide adequate strength in the final weldment. Other applications, however, may need to be stress-relieved. Stress-relieving is a process by which the weldment and base material are heated per a time/temperature schedule (it varies according to application), held at that temperature, and then ramped down slowly and evenly cooled. The process reduces residual stresses in the weldment that could lead to premature failure, e.g. creep rupture, fatigue or cracking. As with any welding application, when joining dissimilar materials, it is necessary to select a filler metal that can withstand this stress-relieving process. As a note of caution, itis also necessary to consider the impact of this process on the materials, as some types of steel (quenched and tempered, for examples) can lose their mechanical properties when stress relieved at elevated temperatures, What's Next? Fortunately, while it takes good skill and an even greater knowledge to weld dissimilar strength carbon and low alloy steels, the process doesn't have to be overwhelming. Instead, considering a few basic factors and selecting the correct filler metals for the application can significantly improve the chances of success. Consulting with a trusted welding distributor, steel producers, and/or filler metal manufacturer can also help. ipuhwwrhobertorcthers.comindex pop?mact=News cin print erin arileié=S68crin0tshowlamplate=flseBcrintOteturide523