WELDING OF

STAINLESS STEEL &

ALUMINIUM
 WHAT MAKES STEEL BECOMES
STAINLESS STEEL?
► Presence of Cr > 12% & Ni
► Formation of stable layer of protective chromium-
chromium-
rich oxide on surface (important on WM too) – for
stainless characteristic
► Fe, C, Cr & Ni - primary elements
► Cr retards rust → increase corrosion resistance
 Problem when welding SS !
► Localised corrosive attack (on HAZ
longitudinally)
► WM & HAZ cracking
► Ductile to Brittle Fracture Transition
(Embrittlement)
 CLASSIFICATION OF STAINLESS
STEEL
► Ferritic
SS (10-
(10-28%Cr, no Ni, no Mo) e.g.
400 series, 407, 430
► Martensitic SS (12Cr-
(12Cr-0.1C wt%, no Ni, +
Mo) e.g. 400 series, 410
► Austenitic SS (18Cr-
(18Cr-8Ni wt%) e.g. 200, 300
series
► Duplex SS (Austenitic + Ferritic) e.g. 329
 ELEMENT STABILISER
► Elements which like Cr (Ferrite Stabilisers)
→ Promote Ferrite → Ferritic SS
► Elements which like Ni(AuteniteStabilisers)
→ Promote Austenite → Austenitic SS
CHARACTERISTIC OF FERRITIC SS
► Good resistance to chloride SCC
► Poor toughness
► Non Hardenable, Magnetic
► Coeff of Thermal Exp < Austenitic (about same as
Mild Steel)
► Higher yield strength, lower ductility than
austenitic SS
► Exhibit ductile-
ductile-to-
to-brittle fracture behaviour as CS
 WELDABILITY OF FERRITIC SS
► Generally Weldable, Fusion Welded
► DO NOT weld using Oxy fuel gas Process, Carbon Arc Process
and CO2 W (not recommended) – Carbon pickup (formation of
CrC)
► Course grained HAZ – poor toughness → cracks
► Lower Cr → harden, martensites at GB
► Thick section require preheat ~ 200 oC and solution annealed
at 760 – 820 oC, water or air quench to improve Q & restore
full CorRes (due to dissociation of CrC).
► For better impact resistance – use austenitic SS filler metal
► For normal application match with the base metal
► Weld embrittlement possible when prolong used at high
temperature
► < 6 mm thickness – no special precaution necessary
► Thick section – needs low heat input to control grain
coursening
 CHARACTERISTICS OF
MARTENSITIC SS
► Higher C (hard) → cracks
► ~ 11.5 – 18% Cr, C as high as 1.2%
► Good tensile, creep, fatigue strength (can be used
for high temperature environment)
► BCC alloy of Cr & C
► In hardened condition(martensitic) – BCT (Body-
(Body-
centred tetragonal)
► Ferromagnetic & hardenable
► CorRes < other SS (due to higher C content, CrC)
WELDABILITY OF MARTENSITIC SS
► Mostdifficult to weld
► Need special welding procedure
► Need tempering between 600 -750 oC (to
balance hardness & toughness)
CHARACTERISTICS OF AUSTENITIC SS
► 16-26%Cr, 8
16- 8--22%Ni
► 300 series, 316 (marine application)
► Type 304 18%Cr, 10%Ni (Basic) – commonly used for
welded fabrication
► Non Magnetic
► 50% of SS production
► Solidification & liquation cracking common
► Thermal expansion > other SS → distortion, residual
stresses
WELDABILITY OF AUSTENITIC SS
► Possible welding processes s.a. GTAW, GMAW, SMAW,
SAW
► Weld pool viscous →slow metal flow, low wettability →
lack of fusion
► Need relatively high travel speed, lower current – reduce
heat input, prevent carbide precipitation → minimise
distortion
► Control interpass temp (CrC formed bet. 500 – 850o C)
► To weld 304 SS, 308L filler metal is recommended. (L=Low
C content less than 0.03% to prevent weld decay)
► Good fabrication weldability, low temp toughness
► Poor Chloride SCC resistance, intolerant to contaminants
s.a. S, P & Boron.
► Suitable for Cryogenic application
CHARACTERISTICS OF DUPLEX SS
► Two phase alloy of Fe-
Fe-Cr
Cr--Ni system
► Approx. equal proportions of BCC Ferrite & FCC
Austenite phases & low C
► 20--30Cr, 5
20 5--10Ni
► Good strength, Chloride Stress-
Stress-Corrosion Cracking (SCC)
resistance, pitting corrosion resistance.
► Use in temperature range of ambient to several hundred
deg. F
► Acid & aqueous chloride resistance
► In high Ferritic content – poor low temp toughness
► In high Austenitic content – low strength, low resistance
to chloride SCC
► Suitable for offshore application
 WELDABILITY OF DUPLEX SS
► Better than Ferritic SS, not as good as Austenitic
SS
► Solidification & Hydrogen cracking
► Avoid low heat input welding
► Preheat normally not required
► Control interpass temp
► Filler metal overalloyed with Nitrogen
► Shielding gas may contain Nitrogen
WELDING OF
ALUMINIUM
 CHARACTERISTICS OF
ALUMINIUM
► Light weight, high thermal conductivity, low
melting point
► Easy burnthrough, warpage
► Alloying element Cu,Mn,Si,Mg,Zn
► Al
Al--Mn alloy (1.0-
(1.0-1.2%Mn), Al-
Al-Mg alloy (up to
5%Mg), Al-Al-Mg-
Mg-Mn alloy
► 3 types of Aluminium:
► PureAluminium – 99.7, 99.5, 99.0% Al, non hardenable
► Non heat treatable Al Alloy – Al & Mn
► Strengthincreased thru cold working or strain hardening
by mechanical deformation
► Heat treatable Al Alloy (hardenable)–
(hardenable)–(Cu), (Mg+Si), (Zn+Mg)
► Can be heated after welding to regain strength
 ALUMINIUM SERIES
► 1000 Series - Pure Aluminium
► 2000 - Al & Cu (high strength, aerospace
industry) –limited weldability
► 3000 - Al & Mn (low/medium strength,
beverage cans) – non heat treatable
► 4000 - Al & Si (for welding/brazing filler wire).
Si to lower melting temp hence can be
used for brazing material.
► 5000 - Al & Mg (structural application in sheet
or plate, weldable)
► 6000 - Al, Mg & Si (heat treatable, for
extrusion, sheet & plate, weldable,
crack sensitive, welding must use filler
metal)
► 7000 - Al & Zn (high strength aerospace alloy)
► 8000 - Others
 Aluminium & Aluminium Alloy Designation

Al

Al Cu Mn Si Mg Mg/Si Zn Other
1xxx 2xxx 3xxx 4xxx 5xxx 6xxx 7xxx 8xxx
Electrical, Strength Formability Brazing Strength Strength Strength
Thermal Welding After Extrusionability
Conductivity Filler Welding

Non Heat Treatable

Heat Treatable
 WELDABILITY OF ALUMINIUM &
ALLOY
► Hardenable alloy – difficult to weld, hot cracking
► Cast Al with high Cu or Mg content–
content– unsuitable for welding
► Aluminium Oxide easily formed on welding, needs good shielding (Ar + He)
► Aluminium Oxide melting point high
► Al Oxide can cause welding defects
► Scrap or brush using SS wire prior to welding, brush in one direction.
► Other contaminants s.a. grease, paint cause pores in weld
► Recommended welding methods are GTAW & GMAW
► Use AC with GTAW, Zirconiated tungsten electrode
► Less distortion with GMAW, use push-
push-pull type of welding equipment, DCRP
► Pulse--Arc welding gives less distortion, low defects
Pulse
► Root backing by Cu or steel
► Inert Gas Backing or Purging
► Al & NHT Alloy – filler wire same with BM
► Hardenable Alloy – use high Si or Mg in filler wire to avoid hot cracking, preheating
► 5000 series – shielding by Ar + He, good penetration, minimise MgO
E