Dissimilar Metal Welding

SFI / IWE 2.
22-1
Joining dissimilar materials I
Chapter 2.22-1:
Page 1
2015 GSI - Gesellschaft fr Schweitechnik International mbH
Materials and their behaviour during

welding
Reprinting and unauthorised disclosure are prohibited and will be prosecuted in accordance with the law
SFI / IWE 2.22-1
Page 2
Practitioners entitle all steels with less than about 5% of alloying elements as black materials. This is
due to the fact that these materials are usually supplied with a dark scaling layer and that they rust over
time.
On the other hand high-alloyed materials are referred to as "white", because they have a very bright and
shiny appearance, because they do not rust under normal conditions.
If we count the low-alloy (< 5% alloying elements) steels/cast alloys in the iron and steel list, there are
more than 1000. The high-alloyed steels and alloys are more than 500.
For black-and-white compounds we use about 500,000 different possibilities.
Now if it can be noticed that most black and
white connections can be welded successfully with several welding consumables, so
there are more than 1 million possibilities
with certainty. How can you get an overview here?
A welding connection is, from the perspective of the chemical composition, divided
into three sections:
1. Base material 1:
2. Weld metal
3. Base material 2:
For the material properties of the whole welded joint the properties of both heat affected zones, along
with the weld metal and base material, are important although their properties are changed by heat input
during welding.
The heat-affected zones are however not characteristic for a black-and-white compound, because they
also occur when welding similar materials. Nevertheless, the welding technology for both steels must be
mastered before attempting a black and white bond.
(reduction of high hardnesses in the HAZ)
These are the steps for planning the welding

technology for low-alloy steels. They are
summarised in the chart below.

welding
SFI / IWE 2.22-1
Page 3
For pre-heating there is only one real reason: the avoidance of hydrogen cracking. Many different formulae are used throughout the world, but the best one seems to be the formula of Uwer, published in SEW
088.
The chemical composition of the base
material is determined by a so-called
carbon equivalent CET. Here, the
carbon content of the base material
plays a decisive role.
In the formula of the pre-heating temperature Tp, the wall thickness d in
mm, the inserted amount of hydrogen
HD and the heat input Q in J / cm are
taken into account.
According to a research study by the
SLV, this formula is suitable for practical use.
A programmable calculator or computer program can be used quickly to determine the recommended
preheating and intermediate temperatures for each individual case.

welding
SFI / IWE 2.22-1
Page 4
The weld temperature cycle of a point at a distance r from the weld centre can be calculated using the
following formulas.
In particular the cooling time
t8/5 between 800 and 500 C is
important for the properties of
the HAZ.
The parameters /2 are
collated for submerged arc
welding with constant K3 in
SEW 088.
The K3 dependency on the
preheating temperature takes
into account the temperature
dependency of the base materials thermal conductivity.
In case of using welding processes other than submerged arc welding ( = 1), their relative thermal efficiency have to be taken into consideration.
For two-dimensional heat dissipation the values

c
are summarised in the constant K2 of SEW 088 .
In case of using welding processes other than submerged
arc welding the relative thermal efficiency of the process
is also to be considered again.
It is important to know that for
two-dimensional heat dissipation the temperature cycle and
cooling time t8/5 are influenced
additionally by the wall thickness.
Once again, in case of using welding processes other than submerged arc welding ( = 1), we need to
take into consideration that their relative thermal efficiency is different.
The transition from the 3-dimensional calculation model to the 2-dimensional calculation in SEW 088 is
retrieved when the transition wall thickness d used in both formulas brings out the same t8/5. For wall thicknesses less than d the two-dimensional formula delivers the lowest t8/5, with greater wall thicknesses, the
three-dimensional formula. So the smaller value of the two models is to be set as true. This definition has
proven itself in practice.

welding
SFI / IWE 2.22-1
Page 5
As we have to weld with the same t8/5, which will be explained further on in more detail, for each wall
thickness a new calculation of the welding parameters have to be made in case of a two-dimensional
heat dissipation. In practice therefore, welding with three-dimensional heat dissipation is recommended
in respect to the transition wall thickness (!). The following picture shows the temperature cycle and cooling time t8/5 with the help of a computer program.
The different temperature

cycles apply for distances
rs = 0/0.2/0.4/.../1.8 mm of
the fusion line. Cooling
time t8/5 is practically the
same for all distances.
The peak temperatures
(maximum temperatures)
achieve the melting point
of (low) alloyed materials
of about 1530C at the
fusion line (rs= 0) .
If the peak temperatures are set as a function of the fusion line distance, then the following picture is
given:
In this example the most

dangerous zone within the
HAZ zones is the approx.
0,7mm width high temperature zone which is being
heated over 1200C during
welding.
In this zone the grain forming particles such as AlN,
Nb (C, N). etc. are dissolved and grain growth is
going on.

welding
SFI / IWE 2.22-1
Page 6
The task of welding engineering is now to control the reverse transformation out of this high-temperature
zone by selecting a suitable cooling time t8/5 which enables good material properties.
The following figure shows an overview of the processes occurring in the HAZ during welding operations
Dissolution of particles such as Al-N, Nb(C,N), V(C,N), TiC

Grain growth
Softening of the microstructure, tempering effects
increasing
A too low cooling time t8/5 leads to

the risk of hardening cracks or hydrogen-induced cracking, although
the impact strength of the martensite of modern steels is excellent
due to their high degree of purity.
Another reason for setting limits to
small values of t8/5 is the worse
deformability of an excessive hard
HAZ.
Too long cooling times t8/5 leads to a
fall of impact strength and the yield
strength in the HAZ.
It is not possible to offer an overall recommendation of a favourable t8/5 for a specific steel type because
the range of permissible analyses leading to excessive changes of transformation behaviour.
A great help for setting a
favourable t8/5 is the welding ZTU diagram that has
been determined through
experimentation with the
help of real welding temperature cycles.
This SZTU shows an example. The chosen cooling time t8/5 should be
short enough to prevent
precipitation
of
proeutectoid ferrite, i.e. less
than 11 sec.
Preferable is a transformation in the low area of
the bainite and on the other hand the maximum
permissible hardness of
350 HV should not be exceeded.
This is achieved in this steel analysis with a t8/5 -time of approx 7.5 sec.
A corresponding computer program can be used to determine the most favourable t8/5 -time with a few
clicks of the mouse.

welding
SFI / IWE 2.22-1
Page 7
We keep t8/5 as short as possible so as to achieve the maximum permissible hardness, because this
shows the best toughness in the HAZ.
In order to determine the

required cooling time t8/5
using the welding parameters
according to the before mentioned formulae from SEW
088, it is recommended to
use a computer program
because, for example, graphical determination by hand is
too awkward and timeconsuming.

welding
SFI / IWE 2.22-1
Page 8
When welding with stick electrodes, the welding (travel) speed is often unknown and even difficult to
determine. On the other hand the run-out length (with the electrode welded weld length) is a suitable
size, in order to control the heat input. An analysis of the digital relationships shows that with a constant
run-out length the heat-input is also constant. If we weld e.g. with higher current we also must, due to the
higher deposition rate of the electrode, weld faster in order to obtain the same run-out length. Then the
heat input per cm weld length is nevertheless constant.
In this case to define a run-out length of 210 mm is correct in order to achieve a cooling time of t8/5 = 7.5
sec.
The correlation between run-out length and the heat input is not dependent on the alloy-type of the rod,
but on the coating type of the electrode. This can be traced back to the chemical slag weld metal reactions in the end crater for which additional energy is used or is being supplied from.

welding
SFI / IWE 2.22-2
Joining dissimilar materials II
Chapter 2.22-2:
Page 1
Materials and their behaviour when

welding
SFI / IWE 2.22-2
Page 2
For welding of high alloyed steels these basic rules should be observed.
1.
No preheating
(for what purpose)?
2.
Choice of the filler material

(similar, ferrite content)
3.
Welding process and its parameters

(weld shape, dilution, hot crack line)
4.
Weld metal in the Schaeffler diagram

(Hot crack line, ferrite content)
5.
Post-weld annealing
(Caution: IC field)
These are explained

previous documents.
in
detail
in
In austenitic steels hydrogen-induced

cold cracking does not occur. Therefore
preheating
is
unnecessary
and
in many cases even harmful.
The weld metal of chemically-resistant
steels should solidify primarily ferritic in
order to avoid hot cracking. However, it
should contain less than about 12%
ferrite in order to avoid a ferrite network.
Figure 1: Basic rules for welding high alloyed steels
A postweld heat treatment should be avoided if possible because of the risk of intercrystalline susceptibility.
The characteristic and crucial point for the black and white connections is the weld metal and not the two
base materials with their heat-affected zones, because they will occur even in similar type welding as
well. Therefore, one can classify black and white connections according to the requirements of the weld
metal.
The table divides the black and white

connections into three groups according
to the type of loading of the weld metal.
In Group II, the weld metal must be
resistant to corrosion. As the black weld
metal does not comply with these
requirements, these can only be used in
claddings.
Figure 2: Classification of black & white connections into type of loading groups

welding
SFI / IWE 2.22-2
Page 3
Black-and-white connections occur wherever

high-alloyed steels are used. Wherever the
properties of high-alloy steels are no longer
required, low-alloy steels are used instead.
The weld metal connections of Group I is
preferably welded with a filler material of type
18% Cr, 8% Ni, 6% Mn = 1.4370.
Despite fully austenitic primary solidification
this filler material initiates no hot-cracking
unless the manganese content decreases, for
example to excessive dilution, below about
3.5% Mn. Martensite in weld metals is to be
avoided.
Figure 3: Black & white connections of group I
The weld metal for Group II connections

are best produced with chemically resistant
weld metals such as 1.4302, 1.4551,
1.4576
In order to avoid hot-cracking, the weld
metal should solidify primarily ferritic. The
ferrite content should be less than about
12%, in order to avoid a ferrite network
A weld metal of type 1.4370 is unsuitable
due to low corrosion resistance.
Figure 4: Black & white connections of group II
The weld metal for Group III connections is best

produced with nickel-based filler metals.
They prevent carbon diffusion otherwise the low
alloyed material at the fusion line would be
decarburised combined with a simultaneous
formation of a carbide border in the high alloyed
weld metal.
At both high and low operating temperatures, the
thermal expansion coefficient of the nickel-base
weld metal, which lies in between of the low-alloy
and high-alloy steels, reduces the stresses from
differential thermal expansion.
Figure 5: Black & white connections of group III

welding
SFI / IWE 2.22-2
Page 4
From the requirements of the weld metal, one can derive the appropriate filler material with its chemical
composition and hence its location in the Schaeffler diagram.
From the Schaeffler diagram it must

be clear which target area must be
achieved for the weld metal.
It should be noted that the molten
weld metal is a combination of the
portions of the two base materials
and the filler metal drops (= pure
weld metal).
Figure 6: Target areas for the weld metal
When welding black and white

bonds, welding processes and
welding parameters are favourable if
they lead to a low dilution. Also the
dilution range - depending on the
manual skill of the welder - should be
as small as possible because the
chemical composition of the weld
metal is critically influenced by the
melted base material!
Therefore, e.g. the TIG process is
generally not suitable for black-andwhite connections.
Figure 7: Dilution ranges with various welding processes

welding
SFI / IWE 2.22-2
Page 5
The formation of the weld metal in terms of its chemical composition is shown in the following picture:
The equations shown allow
the chemical composition
of the weld metal to be
calculated with ease. A
computer program can be
used for this purpose.
Filler Metal
XXFM
FM
Pick-up or burn-off X
Droplets=Pure Weld Metal
X PWM X FM X
Base Material 1:
The only significant

inaccuracy of the
calculation is in the
preliminary assessment of
the two dilution values.
These depend on the
welding parameters, the
joint preparation and the
positioning of the electrode.
Base Material 2:
XWM1 (1 A1-A2 ) (XFM X) + A1 XBM1 A2 XBM2

Bild 8: Calculate that weld metal - composition
The welding of connections in Group I with filler metals of type 1.4370 is relatively easy when one
considers the dilution with the black material within limits.
Having a too high dilution
with the black base material,
the weld metal slips into the
austenite and martensite
area which possibly leads to
hardening cracks. The
dilution with the white base
material however, is not as
critical.
The austenitic weld metal
should contain however
more than about 3.5% Mn,
otherwise hot cracking may
occur.

welding
SFI / IWE 2.22-2
Page 6
Group II of the black-andwhite bonds includes

cladding.
The figure shows the
position of the base
material (GW), pure weld
metal (RSG) and weld
metal (SG1) of the
cladding in the Schaeffler
diagram.
If the welding parameters
are correctly adjusted in
terms of dilution with the
base material, the desired
weld metal is obtained, in
this case with 10% ferrite.
When welding a second layer on the first run a low alloy filler material, e.g. type 21% CR, 10% Ni, should
be chosen in order to prevent getting more than about 12% ferrite in the cladding.
If base material and weld

metal are having high
nickel equivalents and
additionally the dilution is
too high, the weld metal
can reach the range of fullaustenitic solidification.
Hot cracking occurs as a
consequence, as the
following picture shows.

welding
SFI / IWE 2.22-2
Page 7
Hot cracks in an austenitic

solidified SAW-strip cladding.
The example shows that the
issue of the primary ferrite
solidification is more important
than the mechanical residual
stresses of the weld which are
very low for surface welding.
When joining cladding plates the issue of the welding technology depends primarily on from which side
the joint is accessible.
When the joint is accessible from both

sides, the black material is welded first,
as shown here
Subsequently, the cladding is closed.
For the first layer one uses e.g. a filler
material of type 24%Cr, 13% Ni. In
order to achieve low dilutions of just 10
to 15% in the first layer, welding with
stick electrodes in piggy-back
technology is to be applied.
Figure 9: Joining of cladding plates
If a second layer is required a filler material of type 21% Cr, 10% Ni is to be used in order to avoid high
ferrite content in the weld metal.

welding
SFI / IWE 2.22-2
Page 8
Note that the welding direction runs

perpendicular to drawing plane.
During welding, the stick electrode
is not directed towards the base
material, but rather towards the
lower area of the previous weldrun.
By doing this it is possible to
achieve dilutions within the range of
10 to 15% but the welders are
especially to be trained for this!
Figure 10: Piggy-back - welding
If the welded joint is only accessible

from the white side, the picture aside
shows the sequence procedure.
The black material is welded in the
usual way and the high-alloy
cladding is closed in piggy-back
technique.
Postweld annealing
avoided if possible.
should
be
Figure 11: Bonding of cladding plates

welding
SFI / IWE 2.22-2
Only accessible from the black side
Page 9
When access is only available from the

black side, the high-alloy cladding must
first be welded with the same type.
The problem then arises that it is not
possible to weld on a high alloy material
with a low alloy filler material.
This is because this would yield a highalloyed martensitic weld metal with the
risk of hardening cracks and hydrogen
induced cracking.
A possible solution is to weld using nickel-based filler material. This has the disadvantage that the lowalloy base material cannot be similarly welded, so that e.g. the required yield strength cannot be
achieved.
Only accessible from the black side

An elegant solution is to buttering the
high-alloy plating with pure iron
electrodes. By using piggy-back
welding technology on the high-alloy
plates it is possible to create a weld
metal similar to 10 CrMo 10 which is
easy to control in technical terms. The
following filling layers can then be
welded in a similar way with low-alloy
filler material.

welding
SFI / IWE 2.22-2
Page 10
When welding Group III joints two criteria are important:

1. Carbon diffusion must be prevented during operation conditions above 300 C. This is achieved by
using a Ni based filler material and
2. The different expansion coefficients of high- and low-alloyed materials must be considered.
High-alloy materials have an appr.
50% higher expansion coefficient
than low-alloyed materials.
Therefore using a filler material with
a expansion coefficient which lies in
between both material groups is
advantageous. This is the case with
Ni based filler materials. During
temperature changes the
mechanical stresses initiated from
the different expansion coefficients
are distributed over both fusion lines.
Therefore this procedure is also
recommended for low operation
temperatures.
Figure 14: thermal expansion coefficients of different steels
Postweld heat treatments of blackand-white joints should preferably

be avoided because the stresses
initiated out of the different
expansions due to cooling cannot
be avoided.
On the other hand, stress relief
annealing with the aim of reducing
excessive hardness in the HAZ of
the low-alloy material is often
necessary.
Tube joint 13 CrMo 4-5 with 1.4571, filler material Inconel 182
The sequence of buttering the low

alloyed material, stress relieving
and finally welding the remaining
joint is advantageous in this case.

welding
SFI / IWE 2.22-2
Page 11
Sample applications according to DIN EN ISO 9692-4

Applicable standard: DIN EN 1011-5, illustration representation acc.to DIN 8553 (withdrawn)
In addition to the plate thickness, the following factors are crucial for the type of joint preparation and the
welding sequence:
-
Accessibility of the weld: one-sided or from both sides
Weldability between base material and cladding is possible
Weldability between base material and cladding can be achieved by applying buttering layer(s)
Weldability between base material and cladding is not possible (intermetallic phases).
Case 1: Weldability between base material and cladding is possible

e.g. non-alloyed steel/CrNi steel, non-alloyed steel /Ni steel
1 a) Accessibility from one side (usually from the base material side)
Base material
M
1. Weld the cladding material using similar materials

2. Rest: over-alloyed (or Ni)
Cladding material
1 b) Accessibility from both sides

Cladding material
1. Weld the base material using similar filler materials

2. Grind out the weld root from the cladding side.
3. Welding of the back run (similar with base material)
4. Weld the buttering layer (over-alloyed)
5. Weld the plating using similar materials
Base material

welding
SFI / IWE 2.22-2
Page 12
Case 2: Weldability between base material and cladding is established via buttering layers.
e.g. steel/copper
Base material
M
1. Weld the cladding using similar filler materials

2. Weld the buttering layer (Ni)
3. Weld the base material in over-alloyed state
Cladding material
Buttering layer

Cladding material

2. Grind out the weld root from the cladding side
3. Welding of the back run (similar with base material)
4. Weld the buttering layer (Ni)
5. Weld the cladding material similarly
Base material
Case 3: Weldability between base material and plating not possible

(intermetallic phases). Steel/titanium; steel/aluminium
Base material
M
1. Weld the cladding material using similar filler materials

2. Apply sheet metal strip (base material)
Cladding material
Strip of sheet metal

Testingand rinsing bore
Base material

2. Welding the back run after grinding
3. Apply capping strip
d + 30 min.
Cladding material
Capping strip
4. Weld the capping strip using similar filler materials

(cladding)
Intermediate material

welding

Dissimilar Metal Welding

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SFI / IWE 2.

Joining dissimilar materials I

Joining dissimilar materials I

2015 GSI - Gesellschaft fr Schweitechnik International mbH

Materials and their behaviour during

SFI / IWE 2.22-1

Joining dissimilar materials I

(reduction of high hardnesses in the HAZ)

These are the steps for planning the welding

2015 GSI - Gesellschaft fr Schweitechnik International mbH

Materials and their behaviour during

SFI / IWE 2.22-1

Joining dissimilar materials I

2015 GSI - Gesellschaft fr Schweitechnik International mbH

Materials and their behaviour during

SFI / IWE 2.22-1

Joining dissimilar materials I

For two-dimensional heat dissipation the values

2015 GSI - Gesellschaft fr Schweitechnik International mbH

Materials and their behaviour during

SFI / IWE 2.22-1

Joining dissimilar materials I

The different temperature

In this example the most

2015 GSI - Gesellschaft fr Schweitechnik International mbH

Materials and their behaviour during

SFI / IWE 2.22-1

Joining dissimilar materials I

Dissolution of particles such as Al-N, Nb(C,N), V(C,N), TiC

Softening of the microstructure, tempering effects

A too low cooling time t8/5 leads to

Materials and their behaviour during

SFI / IWE 2.22-1

Joining dissimilar materials I

In order to determine the

2015 GSI - Gesellschaft fr Schweitechnik International mbH

Materials and their behaviour during

SFI / IWE 2.22-1

Joining dissimilar materials I

2015 GSI - Gesellschaft fr Schweitechnik International mbH

Materials and their behaviour during

SFI / IWE 2.22-2

Joining dissimilar materials II

Joining dissimilar materials II

2015 GSI - Gesellschaft fr Schweitechnik International mbH

Materials and their behaviour when

SFI / IWE 2.22-2

Joining dissimilar materials II

Choice of the filler material

Welding process and its parameters

Weld metal in the Schaeffler diagram

These are explained

In austenitic steels hydrogen-induced

Figure 1: Basic rules for welding high alloyed steels

The table divides the black and white

2015 GSI - Gesellschaft fr Schweitechnik International mbH

Materials and their behaviour when

SFI / IWE 2.22-2

Joining dissimilar materials II

Black-and-white connections occur wherever

Figure 3: Black & white connections of group I

The weld metal for Group II connections

Figure 4: Black & white connections of group II

The weld metal for Group III connections is best