Welding Exam. 4 th year Metallurgy. Part 2. June 2012. Time 90 min.

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Answer the following questions

1. Write notes on carbide precipitation in DSS weldments.

The current commercial grades are low in carbon (less than 0.03 wt%), thereby
essentially eliminating the risk of sensitization and intergranular corrosion from
carbide precipitation.
2. Write notes on preheat for DSS.
- Preheat is generally not recommended for DSS, but may sometimes be specified in
low-nitrogen grades, because thick sections and low heat input welding processes may,
in combination, develop highly ferritic HAZ. For the more highly alloyed DSS, a
preheat can be highly detrimental and reduce corrosion resistance and mechanical
properties.
3. Write notes on post weld heat treatment for DSS.
- Postweld heat treatment (PWHT) is not commonly used except in autogenous welds or
welds with a filler metal composition that exactly matches the base steel. Although not
always necessary, particularly if a nickel-enriched filler metal is used, it is common to
postweld heat treat DSS welded pipe after longitudinal seam welding.
4. What are the electrodes used for welding ASS?
5. What are the electrodes used for welding FSS?
6. What are the electrodes used for welding DSS?
7. What are the electrodes used for welding ASS?
8. What are the electrodes used for welding FSS?
9. What are the electrodes used for welding DSS?
10. What types of ASS can be subjected to stress PWHT at about 600 oC?
11. Preheat and PWHT are mandatory for all ASS. (False or True) (explain why).
12. Preheat and PWHT are mandatory for all FSS. (False or True) (explain why).
13. Preheat and PWHT are mandatory for all FSS. (False or True) (explain why).
14. Discuss the cooling of three filler metals (electrodes) having compositions A, B and C
in the following figure
Welding Exam. 4 th year Metallurgy. Part 2. June 2012. Time 90 min.
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Welding Exam. 4 th year Metallurgy. Part 2. June 2012. Time 90 min.
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Answer the following questions

1- The Cr% in FSS is in the range a-5-10% b- 10.5- 30% c-3-5%

2- FSS are/are not cooling-rate sensitive. (explain the effect of cooling rate)
Because during slow cooling after welding sigma phase, chi phase, carbides, nitrides, can
form, leading to marked embrittlement
3- 0.2% Al is added to group II FSS to restrict the formation of Austenite….. at high
temperatures a- ferrite b- austenite c- martensite d-bainite (Explain)
Austenite transforms to untempered martensite during rapid cooling that occurs after welding.
Untempered martensite is very brittle and hard and may lead to hydrogen induced cracks,
HIC. Hydrogen is introduced from welding consumables (flux, powder, moisture,
contaminated inert gas).
4- Group III ferritic stainless steels (Should/ may not be) preheated or post wel heat treated
(indicate why)
Welding Exam. 4 th year Metallurgy. Part 2. June 2012. Time 90 min.
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Because of (a) very low O, N, and C contents. (b) Higher Cr and Mo contents. (c)They are
also stabilized by Ti. Nb, Ta. Martensite will not form during welding for these reasons
5- Intermediate purity FSS stabilized only with a-Nb b- Ti c-Ti + Nb will show
columnar weld structure with sharply defined centerline and susceptibility for weld cracking
(how to avoid this). 1-C% < 0.01 2-Nb% < 0.01 3-Ti% > 0.01

6- The precipitates that may occur in FSS are …….

1-Sigma (σ =FeCr) at 825 oC 2-Chi (χ= Fe36Cr12Mo10) at 825 oC 3-alpha-prime (α’=Cr
rich alpha) at 475 oC
7- In E-Brite (group III of FSS containing 26 Cr+1Mo +0.1Nb) sigma phase usually Form /
does not form (Why?)
Because σ solvus is low, 675C, σ formation is sluggish at this low temperature.

8- In austenitic stainless steels (ASS) chromium content range from ……. % to ………%
a- 8 to 20 b- 16 to 25 c- 8 to25 d- 16 to 35
9- In austenitic stainless steels nickel content range from ……. % to ………%
a- 8 to 20 b- 16 to 25 c- 8 to25 d- 16 to 35
10- The weld metal in austenitic stainless steel should have more than …. 3 volume %…
a- pearlite b- cementite c-ferrite d- martensite
11- Manganese can reduce hot cracking in ASS because it ties up ……that would otherwise be
available to form low melting phases a- P b- S c- Si d- Mo e- both a & b f-both b
& c g- both c & d
12- If solidification of ASS starts with ……… the tendency for hot cracking is reduced
a- ferrite b-austenite
13- Solidification (hot) cracking is the result of formation of ………….along grain boundaries
a- low melting liquid films b- chromium carbides c- chromium nitrides
14- To improve strength, ductility and pitting resistance the following is added to austenitic
stainless steels
a- Si b- O c- Ar d- N
15- The tendency for sigma phase formation decreases with increasing
a-Cr, Mo, Si b- N, Ni , C
16- To reduce the effects of sigma phase formation and reduce the risk of solidification cracking
the ferrite content in the weld metal should be kept in the range from (Explain)
a- 3-8% b-8 –12% c- 12-16% 1-3%
17- If the ferrite content in the steel is 8 % then the expected amount of sigma phase that may
result upon holding at high temperature for long time is
a- 8% b- less than 8% c- more than 8% (Explain)
18- The formation of chromium rich M23C6 along the austenitic grain boundaries of none-
stabilized stainless steels during slow cooling after welding makes the steel sensitive to
a- Knife-line attack b- crevice corrosion c-pitting d- Intergrainular attack
19- Intergrainular attack may occur in a narrow region in the HAZ which is
a- immediately adjacent to the base metal b- immediately adjacent the fusion boundary
c-somewhat removed from the fusion boundary (Explain your answer)
20- Knifeline attack may occur in a narrow region in the HAZ which is
a- immediately adjacent to the base metal b- immediately adjacent the fusion boundary
c-somewhat removed from the fusion boundary (Explain your answer)
21- In which of the following steels may occur Knife-line attack?
a-316L b-316 c-304l d-347 (Explain your answer).
Welding Exam. 4 th year Metallurgy. Part 2. June 2012. Time 90 min.
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22- The likelihood of solidification cracking (hot cracking) is high/low. (Explain)

- The base material and filler metals have low S and P levels (less than 0.03 wt%),
which in combination with the ferritic solidification reduce the likelihood of
solidification cracking (hot cracking)
23- Hydrogen cracking (cold cracking) resistance is good/ poor. Explain
This is due to the high hydrogen solubility in the austenite and the high percentage of
austenite in the matrix.

24- DSS with 0.2% N have a- very narrow HAZ a- very wide HAZ (explain and discuss).
Because nitrogen increases the the temperature at which ferrite transforms to austenite
reducing the area of ferrite, which will be after cooling from welding temperature the
HAZ.