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Welding Metallurgy Overview

The document discusses welding metallurgy topics for welding inspectors, including how the internal structure of metals can change during welding due to heating and cooling. It covers how the atomic structure of solids and liquids differs, how properties are affected by factors like grain size, alloying, cooling rates, and preheating. Phase diagrams for steel are presented to illustrate the different phases that can form during welding.

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anon_773111244
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© All Rights Reserved
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4 views49 pages

Welding Metallurgy Overview

The document discusses welding metallurgy topics for welding inspectors, including how the internal structure of metals can change during welding due to heating and cooling. It covers how the atomic structure of solids and liquids differs, how properties are affected by factors like grain size, alloying, cooling rates, and preheating. Phase diagrams for steel are presented to illustrate the different phases that can form during welding.

Uploaded by

anon_773111244
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Module 8 - 1

Module 8

Welding Metallurgy for


the Welding Inspector

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Module 8 - 2

Metallurgy

“The science dealing with the internal


structure of metals and metal properties ”

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Module 8 - 3

Welding Metallurgy

“Concerned with the changes occurring in


metals during welding”

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Module 8 - 4

Discussion Topics
 Structures
 Changes on heating
 Changes on cooling
 Heat treatments
 Alloying
 Phases

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Module 8 - 5

Atomic Structure
 Matter made up of atoms
 Atoms are very small
 Electrons orbit atomic nuclei
 Have a home location in solids
 Oscillate around home position

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Module 8 - 6

Atomic Structure - Simple Cubic

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Module 8 - 7

Home Location

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Module 8 - 8

Solids
 Minimum internal energy
 Atoms fixed in place
 Atoms have ‘home’ position
 Atoms vibrating
 Orbiting electrons
 Crystalline structure

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Module 8 - 9

Liquids
 Higher internal energy
 Atoms free to move
 Atoms vibrating more
 Orbiting electrons
 No fixed structure

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Module 8 - 10

Solid vs Liquid

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Module 8 - 11

Thermal
expansion on
Heating

Thermal
contraction on
Cooling
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Module 8 - 12

Welding Stresses (Tensile)


 Remain after welding is completed (residual stress)
 Can cause distortion
– (welding stress exceeds yield strength of material)
 Can cause cracking
– (welding stress exceeds tensile strength of material)
 Residual stress can be as high as yield strength
 Relieved by three methods

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Module 8 - 13

Stress Relieving
 Thermally
 Vibratory
 Peening

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Module 8 - 14

Crystal Structures
 BCC - Body Centered Cubic
 FCC - Face Centered Cubic
 HCP - Hexagonal Close Packed
 BCT - Body Centered Tetragonal

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Module 8 - 15

Common
Crystal
Structures

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Module 8 - 16

Metal
Solidification

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Module 8 - 17

Grain Size Effects


 Fine grained materials
– Have good tensile strength
– Have good ductility
– Have good low temperature properties
 Coarse grained materials
– Have slightly lower strength
– Are slightly less ductile
– Have good high temperature properties

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Module 8 - 18

Alloying

“Adding elements to change mechanical or


physical properties”

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Module 8 - 19

Interstitial
Alloying

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Interstitial Alloying -
Module 8 - 20

Results in Lattice Distortion

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Module 8 - 21

Substitutional
Alloying

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Substitutional Alloying -
Module 8 - 22

Results in Lattice Distortion

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Module 8 - 23

Microstructures
 Metals composed of grains (crystals)
 Very small
 Separated by grain boundaries
 Different phases within grains

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Module 8 - 24

Microstructure
of Iron

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Module 8 - 25

Iron-Carbon
Phase Diagram

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Module 8 - 26

Phases in Steel
 Ferrite
 Cementite
 Austenite
 Bainite
 Pearlite
 Martensite

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Module 8 - 27

Cooling Rates
 Slow - Pearlite - softest
 Moderate - Bainite
 Fast - Martensite - hardest

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Module 8 - 28

Lamellar Appearance of Pearlite

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Module 8 - 29

Martensite

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Module 8 - 30

Tempering

“Restores ductility and toughness and reduces


strength and hardness”

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Effects of Tempering
Module 8 - 31

Temperatures
Alloy is AISI 4142

Tempering temperature
is in degrees F

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Effects of Tempering
Module 8 - 32

Temperatures
Alloy contains 12% Cr

Note reduction in impact


strength at 885 F (475 C)

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Module 8 - 33

Continuous Cooling
Diagram & Jominy
Hardenability Diagram
for 8630 steel. Phase
formed on cooling
varies with cooling
rate.

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Module 8 - 34

Weld Area & Fe - Fe3C Diagram

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Module 8 - 35

Heat Input

Joules/inch = current x voltage x 60


travel speed (in./min)

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Module 8 - 36

Preheat
 Slows cooling rate
 Produces less martensite
 Reduces risk of cracking
 Reduces distortion
 Reduces hydrogen

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Carbon Equivalent
Module 8 - 37

( CE )

CE = % C + % Mn + % Ni + % Cr + % Cu + % Mo
6 15 5 13 4

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Module 8 - 38

Examples of Preheating vs C.E.


C.E. Preheat Temperature

< 0.45 Optional


0.45 - 0.60 2000 - 4000 F
>0.60 4000 - 7000 F

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Module 8 - 39

Heat Treatments for Steels


 Super-critical - above transformation temp.
– Annealing
– Normalizing
– Quenching (to harden)
 Sub-critical - below transformation temp.
– Tempering
– Stress Relieving

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Module 8 - 40

Diffusion

“Movement of atoms within a solution, be it a


solid, liquid or gas”

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Module 8 - 41

Diffusion of Lead and Gold Atoms

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Module 8 - 42

Solubility
Dissolving Salt into Water
 Solid into liquid
 Diffusion mechanism
 Solubility limit
 Temperature effects

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Module 8 - 43

Solid Solubility
 Unique to metals
 Solid into solid
 Solubility limit
 Temperature effects

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Module 8 - 44

Examples of Solid Solubility


 Gold and lead bars
 Carburizing
 Nitriding

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Module 8 - 45

Stainless Steels
 Ferritic
 Martensitic
 Austenitic
 Precipitation Hardening (PH)
 Duplex

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Module 8 - 46

Sensitization of Austenitic Alloys

“Formation of chromium carbides between


800 - 1600 degrees F”

(Sensitization reduces the corrosion resistance


in many environments)

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Corrosion Attack of Austenitic
Module 8 - 47

Stainless Steel

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Module 8 - 48

Avoiding Sensitization
 Heat treatment ( SAWQ )
 Stabilized grades
 Low carbon grades

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Module 8 - 49

Other Common Alloys


 Aluminum
– Pure aluminum
– Aluminum-copper
– Aluminum-magnesium
 Copper
– Pure copper
– Brasses
– Bronzes
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