Beruflich Dokumente
Kultur Dokumente
ABSTRACT
Purpose: Weld residual stress and thermal stress is to be analyzed for dissimilar metal SMAW
welding of stainless steel to carbon steel. This paper is to investigate the effect of heat input due
to change in the welding speed and its influence on residual stress distribution in weldments.
ASME section 9 and AWS handbook provides generalized guideline for welding and testing
requirements of dissimilar metal like Carbon steel to Stainless steel, welding with above
information may not be practical or not sufficient in highly critical job. Sometimes, compliance
with codes and standard is not sufficient and patterns of residual stress and microstructure
analysis are recommended as and when demanded in critical jobs.
Findings: Residual stresses in restrained welds and weld repairs are very complex. The heat
input affects the value and distribution of residual stress in the specimen. This peak stress in all
samples occurred not at the toe, but in the middle of the weld bead, where the yield stress is
higher. From the results, we discussed that increase in heat input will increase the residual
stress.
Research implications: Measurements of residual stress can be very expensive and time
consuming. The XRD machine is capable of non-destructive investigation of residual stresses in
specimen. Weld area can be recorded where high heat inputs are applied and prediction of
stress value and metal structure change can be predicted using experimental data of the
research paper. The results may be used to calibrate finite element modelling of the welding
process.
Practical implications: Prediction of residual stress and metal structure will add significant
value in predicting equipment’s behavior in service condition. The findings have important
consequences with respect to design of welding procedures and fitness-for-purpose
assessments.
Originality/value: The authors have used X-Ray Diffraction followed by radiography and
metallography assessment of residual stresses to follow in detail the changes due to heat input
in welded specimen. This paper could be an interesting source of information for engineers and
researchers who work with welded structures of dissimilar metal.
Keywords: SMAW Welding; Residual stresses; XRD; Heat input, Welding Radiography
1. INTRODUCTION resulting in a complex micro structure. The
subsequent heating and cooling results in
Welding is extensively used in fabrication as
setting up internal stresses and plastic strain in
an alternative method for casting or forging and
the weld.
as a replacement for bolted and riveted joints. It
Depending upon the slope of
is also used as a repair medium e.g. to reunite a
temperature gradient three distinct zones as
metal at a crack or to build up a small part that
shown in Figure 2 can be identified in welded
has broken off such as a gear tooth or to repair
joint which are:
a worn surface such as a bearing surface.
1. Base metal
2. Heat Affected Zone (HAZ)
3. Weld metal
3. EXPERIMENTAL PROCEDURE
3.2 Welding Procedure
3.1 Parent Metal
Plates of dimensions (100 × 150 × 4)
mm were cut from a large sheet of the mild steel
and finished by machining. In order to perform Table 4 Taguchi L9 array design for Experiments
welding operation the finished plates were again
cut transversally into equal halves of (1×125×15) Sample Voltage Current Time Length Speed Weld
mm for groove preparation as required in the No (V) (A) (Sec) (mm) mm/min Pass
present study. Before welding, the plates’
surfaces were cleaned, thoroughly using both 65.2 150 136.6 Root
chemical and mechanical processes. This was 20 to
S1 75 78.2 150 115.1 Pass 1
done to remove any types of contaminations, 22
which may results from oil, grease, corrosive 66.0 150 136.4 Main
products etc. to obtain a good quality weld [8]. 49.3 150 182.5 Root
20 to
Table 3. Detailed welding parameter descriptions S2 75 62.9 150 143.1 Pass 1
22
65.3 150 137.8 Main
Weld Layer(s) Initial Rest 40.6 150 221.7 Root
20 to
Process GTAW SMAW S3 75 49.0 150 183.7 Pass 1
22
309L- 47.0 150 191.5 Main
Filler lass R 309L
16,17
Metal 65.3 150 137.9 Root
Dia.(mm) 2/2.4 2.5/3.2 20 to
Type DC DC S4 90 77.6 150 116.0 Pass 1
Current 22
Polarity EN P 64.0 150 104.6 Main
(A)
Amp. Range 60-110 60-100 54.8 150 164.2 Root
Volt Range (V) 10-15 20-30 20 to
S5 90 60.2 150 149.6 Pass 1
Speed 22
Travel 4-6 4-10 61.0 150 147.6 Main
(cm/min.)
45.6 150 197.4 Root
The welding of two dissimilar metal is done 20 to
S6 90 44.2 150 203.8 Pass 1
according to welding producer specification by 22
45.8 150 196.7 Main
using SMAW welding. SS309L is used as the
welding electrode. 47.2 150 190.6 Root
20 to
S7 105 64.2 150 140.3 Pass 1
22
52.0 150 173.1 Main
51.8 150 173.7 Root
20 to
S8 105 61.9 150 145.4 Pass 1
22
50.0 150 180.0 Main
27.4 150 328.3 Root
20 to
S9 105 40.2 150 223.8 Pass 1
22
33.5 150 268.7 Main
RESIDUAL RESIDUAL
4.3.2 Discussion STRESS STRESS
SAMPLE
EXPERIMENT ANALYTCAL
From the results, when there is an increase (MPa) (MPa)
in heat input will increase the residual S1 309.9 626
stress. S2 847 556.1
Following graph suggest that increase in S3 617 525
heat input will increase the residual stress S4 697 557
S5 710 542.8
S6 516 532
S7 283.1 555.8
S8 402.2 547.5
S9 203.8 502
Technol. 16 (2000) 688–694.
[3] S. P. Tewari, ankur gupta , jyoti prakash
,2010. “effect of welding parameters on the
weldability of material”.international journal
of engineering science and technology, vol.
2(4), 2010, 512-516
[4] Welding Journal, Vol. 42(1), pp.38-46.
[5] O P Khanna (2001), “A Text Book of
Figure 7. Residual stress vs Heat Input Graph
Welding Technology”, Dhanpat Rai
Publications, pp. 570-577.
5. CONCLUSION [6] S. Sabooni, F. Karimzadeh, M.H. Enayati, et
al., Friction-stir welding of ultrafine grained
Residual stresses in restrained welds and
austenitic 304L stainless steel produced by
weld repairs are very complex. The heat input
martensitic thermomechanical processing,
affects the value and distribution of residual
Mater. Des. 76 (2015) 130–140.
stress in the specimen. This peak stress in all
[7] W.Wu, S. Hu, J. Shen, Microstructure,
samples occurred not at the toe, but in the
mechanical properties and corrosion
middle of the weld bead, where the yield
behaviour of laser welded dissimilar joints
stress is higher. From the results, As the Heat
between ferritic stainless steel and carbon
Input is increase, there is an increase in the
steel, Mater. Des. 65 (2015) 855–861.
residual stress.
[8] L.-E. Svensson: Control of microstructure
From the above results and discussion, It is and properties in steel arc welds, CRC
concluded that, carbon steel has higher heat Press, Inc., 1994
transfer rate compare to stainless steel, due to [9] Deng D, Liang W, Murakawa H.
that reasons all the properties likes change in Determination of welding deformation in fillet
thermal expansion, metallography structure, welded joint by means of numerical
thermal conductivity and cooling rate is simulation and comparison with experiment.
occurred in the carbon steel is fast compare [10] Mater Sci Eng a 2008; 487:210–8. Deng D.
to stainless steel. FEM prediction of welding residual stress
and distortion in carbon steel considering
6. REFERENCES phase transformation effects. Mater Des
2009. ;30: 66
[1] Bhargav C Patel, Jaivesh Gandhi, 2013.
“Optimizing and analysis of parameter for
pipe welding: A literature
review”, International Journal of
Engineering Research & Technology, Vol.2
- Issue 10, (October - 2013),2278-0181
[2] Y.S. Tarng, W.H. Yang, S.C. Juang, “ The
use of fuzzy logic in the Taguchi Method for