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MECHANICAL CHARACTERISTICS OF GAS METAL ARC WELDING OF ASTM A

516 GRADE 70 STEEL

Article  in  International Journal of Applied Engineering Research · January 2015

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 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.68 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm
MECHANICAL CHARACTERISTICS OF
GAS METAL ARC WELDING OF ASTM A
516 GRADE 70 STEEL
K SIVAKUMAR1, T.M.SARAVANA MANIKANDAN2, S.BALAGURU3,R.SABARISH4,J.MANIKANDAN5
1,3
Research Scholar , Dept of Mechanical Engineering, Anna university
2
Dr.M.G.R.Educational and Research Institute
4,5
Assistant Professor, Dept of Mechanical Engineering,BIST
Ksivakumar2476@gmail.com
ABSTRACT - The metal that we are focused on
studying is ASTM A516 grade 70 and is one of the most
popular boiler and pressure vessel grade of the steel
plate in the industry. The name SA516 is the ASME
boiler and pressure vessel code for this particular
material. It is a medium carbon steel produced in
grades 55, 60, 65 and 70 out of which 70 is the most
common. It has high quality carbon steel plate for boiler
and pressure vessel fabrication which is ideally suited to
the high standards asset by the oil, gas and
petrochemical industry. The SA516 grade 70 offers
greater tensile and yield strength when compared to
SA516 grade 65 and can operate in even lower
temperature service. The welding that we are focused
on is the Gas Metal Arc Welding (GMAW) or Metal
Inert Gas (MIG) welding and it is one of the most
widely used processes in industry. GMAW process with
either solid or metal cored welding wires have gained
the most popularity among the different types of
welding because high quality and eco9nomical welds
can be obtained. Relatively large metal deposition rates
are achieved by GMAW process. The major advantage
of gas metal – arc welding is that high quality welds can
be produced much faster than with SMAW or TIG
welding. Since a flux is not used, there is no chance for
the entrapment of slag in the weld metal. This process is
versatile and can be used with a wide variety of metals
and alloys, including aluminum, copper, magnesium,
nickel, and many of their alloys, as well as iron and
most of its alloys. The process can be operated in
several ways, including semi – and fully automatic.
MIG welding is widely used by many industries for
welding a broad variety of materials, parts, and
structures.
The present objective of the investigation is to
analyze the mechanical and metallurgical behavior of
GMAW on ASTM A516 grade 70 and also to find the
effect of input parameters such as welding current,
stand of arc, travel speed, wire feed rate on hardness
behavior.
I.INTRODUCTION
In the boiler and pressure vessel industries,
carbon steel and alloy steels dominate the usage and
form the major percentage of materials being used.
822
These materials are being used in a variety of product
form in the industries such as plates, tubes pipes etc.
Most of the products are being used in the final
assembly in the welded form; the welding process
being selected depends upon the functional
requirement of the final product. The mechanical
properties of a material are influenced by the method
and parameters used for its fabrication. The variation
in the material properties can be substantiated during
the different stages of fabrication.
Carbon steels:
Almost all of the material used in
constructing boilers and pressure vessels and steel
and the vast majority of components are made of
carbon steels. It is used for most types of pressure
and non pressure parts such as drums, headers,
piping, tubes, structural steel, flues and ducts.
Low carbon steel → 0.15% C maximum
Medium-Low carbon steel → 0.15-0.23% C
Medium-High carbon steel → 0.23-0.44% C
High carbon steel → more than 0.44% C
Gas Metal-Arc Welding
Gas Metal-Arc Welding (GMAW), also
called Metal Inert Gas (MIG) welding, shields the
weld zone with an external gas such as argon, helium,
carbon dioxide, or gas mixtures. Deoxidizers present
in the electrode can completely prevent oxidation in
the weld puddle, making multiple weld layers
possible at the joint. GMAW is a relatively simple,
versatile, and economical welding apparatus to use.
This is due to the factor of 2 welding productivity
over SMAW processes. In addition, the temperatures
involved in GMAW are relatively low and are
therefore suitable for thin sheet and sections less than
¼ inch. GMAW may be easily automated, and lends
itself readily to robotic methods. It has virtually
replaced SMAW in present-day welding operations
in manufacturing plant
 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.68 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm

II BASE METAL manganese, 0.035 percent phosphorus, 0.04 percent

Tensile Strength:
A516-70N carbon steel plates can withstand
70,000 pounds per square inch (psi) to 90,000 psi. Its
yield strength is 38,000 psi. Grade 70 represents the
strongest carbon steel plates specified by the ASTM
(American Society for Testing and Materials).
Composition:
A516 grade 70 carbon steel plates are composed
of 0.31 percent carbon, 085 percent to 1.20 percent
  A516 Grade 70
sulfur and 0.15 percent to 0.30 percent silicon. These
are the highest percentages found in carbon steel
compositions.
Mechanical Properties:
Tested at temperatures of 25 degrees Centigrade,
ASTM A516 grade 70 carbon steel has a density of
7.7 to 8.03, a Poisson's ratio of 0.27 to 0.30 and an
elastic modulus of 190 to 210.

Tensile Strength (ksi) 70-90

Tensile Strength (MPa) 485-620

Yield Strength (ksi) 38

Yield Strength (MPa) 260

Elongation in 200mm (%) 17

Elongation in 50mm (%) 21

Max Thickness (mm) 205

Table 2.1 Mechanical Properties

Chemical composition of the Base material (wt. %)

C Mn Si S P Cr Ni Cu

0.21 1.14 0.22 0.008 0.014 0.03 0.015 0.023

                                Table 2.2 Chemical composition 

Al N V Mo Ti As Nb

0.026 0.0089 0.02 0.02 0.005 0.005 0.02

Table 2.3 Chemical composition

III. WELDING PROCESS 

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 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.68 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm
Fig. 3.1 Gas metal Arc welding Equipments  bent nozzle fitted at the end. A bent nozzle can be
Gas Metal Arc Welding (GMAW) or
Metal Inert Gas (MIG) welding is one of the most
widely used processes in industry. GMAW process
with either solid or metal cored welding wires have
gained the most popularity among the different
types of welding because high quality and
economical welds can be obtained.
The GMAW process uses either
semiautomatic or automatic equipment. GMAW
can be easily mechanized and produces smooth,
neat clean and spatter free welded surfaces which
require little or no further cleaning thereby
reducing total welding equipment cost. Relatively
large metal deposition rates are achieved by
GMAW process
Principle of operation:
        
Fig. 3.2 Metal Arc Welding Process
GMAW is an arc welding process wherein
coalescence is produced by heating the job with an
electric arc established between a continuously fed
metal electrode and the job, shielded by an inert
gas such as argon, helium, carbon dioxide or a gas
mixture. As the equipment
Provides for automatic self regulation of
the electrical characteristics of the arc and the
deposition rate, the only manual controls required
by the welder for semiautomatic operation are the
gun positioning, guidance and travel speed. The arc
length and the current level are automatically
maintained
Equipment:
Power sources processing flat or dooping
characteristics and rated at 400 amps can be
employed for mig welding. Flat characteristic
welding sources ensure a more constant arc length.
The major types of power sources are dc generator
or AC transformer with rectifier. DC electrode
positive (DCEP) is preferred for its better cleaning
action. AC is generally
not recommended because of unequal burn off
rates during negative and positive half cycles.
The welding torch energises the
electrode, feeds the electrode and the shielding gas.
The torch may be air cooled or water cooled.
Torches working above 200 Amps are generally
water cooled. The torch may have a straight or
824
used for welding complicated shapes and intricate
joints.
Wire feed mechanisms may deliver
electrode to the torch at constant speed or at
different speeds. The wire spool, in manually
operated units, is mounted elsewhere to facilitate
welding over a bigger area whereas in automatic
machines, the wire spool is fixed on the same
carriage over which the torch is mounted. The
different diameters of the electrode wire are 0.8 ,
1.2,1.6 mm etc. a standard wire spool may have
from 1 to 15 kgs of wire.
Polarity:
a) Direct current Electrode Negative
(DCEN)
This is also called the straight
polarity in which the electrode is connected to the
negative terminal of power supply. Electrons are
emitted from the electrode and accelerated while
traveling through the arc. When the electrons enter
the work piece, an amount of energy equivalent to
the work function is released.
b) Direct current electrode positive (DCEP)
This is also called reverse polarity. The
electrode is connected to the positive terminal of
the power source. The heating effect of the
electrons is now at electrode rather than at work
piece. DCEP can be used for welding thin sheets of
strong oxide forming materials where deep
penetration is not required.
c) Alternating Current (AC)
AC MIG welding is not very common,
negative polarity of the electrode means lower heat
input and higher deposition rate. For the AC MIG
welding, special power sources are used that
produce a square wave AC current.
Shield gas
The primary function of the
shielding gas is to protect the molten metal and the
electrode from atmospheric contamination
especially nitrogen and oxygen as the weld pool is
being formed. The gas also promotes a stable arc
and uniform metal transfer. The quality, efficiency
and overall operating acceptance of the welding
operation are strongly dependent on the shielding
gas, since it dominates the mode of metal transfer.
The shielding gas not only affects the
properties of the weld but also determines the
shape and penetration pattern as well. During
welding, the shielding gas also interacts with the
 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.68 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm
welding wire to produce the strength, toughness
and the corrosion resistance of particular weld
deposits. The shielding gas also affects the residual
contents of the hydrogen, nitrogen and oxygen
dissolved in the weld metal. In GMAW or MIG
welding process, shielding gas plays an important
role. For welding SA 516 G70, a mixture of argon
and CO2 is used as the shielding gas. Argon Gas
reduces the spatter loss during the welding. But if
the amount of argon exceeds 90%, it would result
in weak and poor weld appearance. The CO2 gas
added to the mixture increases the depth of weld
penetration but cannot be increased to the great
extent as it would proportionally increase the rate
of the spatter loss.
Hence, for clean, strong and proper weld,
the amount of argon gas is generally maintained
between 80-90%. In this work the welding of SA
516 G70 is performed for the hardness of the weld
at different current amps, travel speed, wire feed
rate, standard arc distance
The choice of shielding gas made a lot of
difference to the ease of welding. Argon/CO2 mix or
Argo shield result in easier and neater welds given an
unrestricted choice of gas
Seven effects of shielding gas:
Although you probably know that shielding
gas is essential in most welding procedure
specifications, you may pay little attention when
you're selecting it. A simple gas composition change
can offer potential savings in seven key areas,
particularly in gas metal arc welding (GMAW).
Shielding gas typically isn't considered to
have much of an effect on the cost of a welding
operation. Many welders don't fully understand the
financial impact that shielding gas can have on the
bottom-line cost of the welding operation.
Which shielding gas composition you
choose for GMAW can affect your welding operation
in seven key ways.
Filler Metal Deposition Rate and Efficiency:
Shielding gas blends with high argon content
generally result in high productivity. Placing the
work piece in the flat or horizontal welding position
allows you to use spray transfer with these blends.
Select shielding gas carefully: Wire feed rates and
current levels are high.
Single-wire GMAW can exceed deposition
rates of 15 pounds per hour at 100 percent duty cycle.
Argon content should be 85 percent or more to
accomplish spray transfer. In some cases, instead of
using a conventional argon/carbon dioxide or
argon/oxygen blend, using a helium-enhanced argon
825
blend may increase weld metal deposition rates up to
15 percent.
Although helium costs more than argon,
shielding gas typically comprises less than 5 percent
of the total welding cost, making the addition of
helium something to consider when choosing a
shielding gas blend.
Electrode deposition efficiency is linked
directly to the welding spatter level. High-argon
blends typically produce the best results in spray
transfer. Improved deposition efficiency also can be a
function of choosing the right welding parameters. A
non optimized system—in which any number of
parameters, such as gas flow rate and voltage, aren't
optimized—generally produces lower deposition
efficiency and may contribute to increased post weld
cleanup costs.
Welding gun:
The typical GMAW welding gun has a
number of key parts—a control switch, a contact tip,
a power cable, a gas nozzle, an electrode conduit and
liner, and a gas hose. The control switch, or trigger,
when pressed by the operator, initiates the wire feed,
electric power, and the shielding gas flow, causing an
electric arc to be struck. The contact tip, normally
made of copper and sometimes chemically treated to
reduce spatter, is connected to the welding power
source through the power cable and transmits the
electrical energy to the electrode while directing it to
the weld area. It must be firmly secured and properly
sized, since it must allow the passage of the electrode
while maintaining an electrical contact. Before
arriving at the contact tip, the wire is protected and
guided by the electrode conduit and liner, which help
prevent buckling and maintain an uninterrupted wire
feed. The gas nozzle is used to evenly direct the
shielding gas into the welding zone—if the flow is
inconsistent, it may not provide adequate protection
of the weld area. Larger nozzles provide greater
shielding gas flow, which is useful for high current
welding operations, in which the size of the molten
weld pool is increased. The gas is supplied to the
nozzle through a gas hose, which is connected to the
tanks of shielding gas. Sometimes, a water hose is
also built into the welding gun, cooling the gun in
high heat operations.
 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.68 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm
Fig. 3.3 Gas Metal Arc Welding Gun
The wire feed unit supplies the electrode to
the work, driving it through the conduit and on to the
contact tip. Most models provide the wire at a
constant feed rate, but more advanced machines can
vary the feed rate in response to the arc length and
voltage. Some wire feeders can reach feed rates as
high as 30.5 m/min (1200 in/min), but feed rates for
semiautomatic GMAW typically range from 2 to
10 m/min (75–400 in/min).
Welding Gun Types
The most common welding gun is a hand
held air-cooled gun, it is used for general welding.
The second most common type of welding torch is
water-cooled; it uses higher current levels for heavier
sections and larger wire diameters. The third typical
holder type is an automatic gun that is water cooled;
this gun is used typically with automated equipment.
Hardness measurements:
The Term Hardness may be
defines as the resistance of the material to plastic
deformation usually by indentation when in contract
with an indenter under load. Hardness may be
measured by various hardness tests such as brinell,
Rockwell, Vickers, Knoop tests etc. Generally, a
Hardness test consists of Pressing and Indenter of
known geometry and mechanical properties into the
test material. The hardness of the material is
quantified using one of the varieties of scales that
directly or indirectly indicate the contact pressure
involved in deforming the test surface. Since the
indenter is pressed into the material during testing,
hardness is also viewed as the ability of a material to
resist compressive loads. The indenter may be
spherical, pyramidal or conical. In the Brinell,
Vickers and Knoop tests, hardness value is the load
supported by the unit area of the indentation,
expressed in kilogram, per square millimeter
(kg/mm²) In the Rockwell tests, the depth of
indentation at a prescribed load is determined and
converted to a hardness number without
826
measurements units, which is inversely related to the
depth. Unlike other test methods, Rockwell testing
needs no surface preparation, polishing etc of the
specimen whose hardness is to be measured.
Rockwell Hardness Testing Machine
Specification:
Rockwell test minor load is 10 kgf & major loads
are 60, 100, 150 kgf.
Rockwell hardness scales such as hra, hrb, hrc, etc.
Is obtained by using different types of indenters
(diamond / ball).
Test height x throat is - 215 x 132 mm
Principal of the Rockwell Test:
1. The indenter moves down into position on
the part surface
2. A minor load is applied and a zero reference
position is established
3. The major load is applied for a specified
time period (dwell time) beyond zero
4. The major load is released leaving the minor
load applied
The resulting Rockwell number represents
the difference in depth from the zero reference
position as a result of the application of the major
load.
There are two scales on a Rockwell Testing
machine, ie ‘B’ scale and ‘C’ scale. ‘B’ scale uses a
steel ball indenter whereas a diamond cone penetrator
is employed for measuring hardness on a ’C’ scale.
‘B’ scale is for testing materials of medium hardness
such as low and medium carbon steels, in the
annealed condition. The working range of this scale
is from 0 to 100. ‘C’ scale is used for testing
materials harder than B. ‘C’ scale is commonly used
for testing the hardness of alloy cast irons. In
Rockwell hardness testing, the minor load for all the
cases is 10 kg whereas major loads for scales C and B
are 150 and 100 Kg respectively. In the present work,
the hardness of the weld specimens are measured in
Rockwell ‘C’ scale using a 120° diamond cone
indenter under a load of 150 kg.
 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.68 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm

Diagram of the welding areas to be tested:

Fig. 3.4 welding areas to be tested

P = Penetration
W = Width
TA = Total Area
R = Reinforcement area

IV. DESIGN OF EXPERIMENTS

Expt.No Coded value Original Value

A T F S A T F S
1 -1 0 -1 -1 75 6 50 5
2 -1 +2 +1 -1 75 8 70 5
3 -1 -1 -2 -1 75 5 40 5
4 -1 -2 -2 -1 75 4 40 5
5 -1 -1 -2 +1 75 5 40 7
6 -1 +2 +2 +1 75 8 80 7
7 -1 +1 -1 +1 75 7 50 7
8 -1 -2 -2 +1 75 4 40 7
9 +1 +2 +2 +1 95 8 80 7
10 +1 -2 -1 +1 95 4 50 7
11 +1 +1 0 +1 95 7 60 7
12 +1 0 0 +1 95 6 60 7
13 +1 +1 +1 -1 95 7 70 5
14 +1 -2 -2 -1 95 4 40 5
15 +1 0 -1 -1 95 6 50 5
16 +1 +1 +1 -1 95 7 80 5
17 -2 +2 -1 -1 65 8 50 5
18 +2 +1 +1 +2 105 7 70 8
19 0 +1 0 0 85 7 60 6
20 0 0 -1 0 85 6 50 6
21 0 +2 +2 0 85 8 80 6
22 0 -2 -1 0 85 4 50 6
23 0 +2 +1 -2 85 8 70 4
24 0 +2 +2 +2 85 8 80 8

V.CONCLUSION following conclusion has been drawn from the

The effect of the post weld heat treatment on results: The five factor design was developed. We
the weld properties of SA 516 Grade 70 in Gas Metal found that the welding current is increasing the
Arc Welding (GMAW) was investigated. The hardness of welded area marginally increased. The

827
 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.68 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm
hardness of the weld material in the weld bead is
found that weld parameter at (Current, Travel Speed,
Length Wire Feed, Stand off arc = 85, 6, 50, 6) and
having a hardness of 137.5 HRC will have the high
welding hardness. The hardness of the weld material
in the weld bead is found that weld parameter at
(Current, Travel Speed, Length Wire Feed, Stand off
arc = 95, 4, 40, 5) and having a hardness of 50.5
HRC will have the low welding hardness. The
hardness of the weld material in the heat affected
zone is found that weld parameter at (Current, Travel
Speed, Length Wire Feed, Stand off arc = 75, 7, 50,
7) and having a hardness of 139.75 HRC will have
the high welding hardness. The hardness of the weld
material in the heat affected zone is found that weld
parameter at (Current, Travel Speed, Length Wire
Feed, Stand off arc = 95, 4, 40, 5) and having a
hardness of 42 HRC will have the low welding
hardness.
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