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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Welding Metallurgy
Concerned with the changes occurring in
metals during welding
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Discussion Topics
Structures
Changes on heating
Changes on cooling
Heat treatments
Alloying
Phases
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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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Atomic Structure - Simple Cubic
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Home Location
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Solids
Minimum internal energy
Atoms fixed in place
Atoms have home position
Atoms vibrating
Orbiting electrons
Crystalline structure
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Liquids
Higher internal energy
Atoms free to move
Atoms vibrating more
Orbiting electrons
No fixed structure
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Solid vs Liquid
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Thermal
expansion on
Heating
Thermal
contraction on
Cooling
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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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Stress Relieving
Thermally
Vibratory
Peening
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Crystal Structures
BCC - Body Centered Cubic
9 atoms, room temperature
FCC - Face Centered Cubic
14 atoms, over 1700
HCP - Hexagonal Close Packed
BCT - Body Centered Tetragonal
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Common
Crystal
Structures
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Metal
Solidification
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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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Alloying
Adding elements to change mechanical or
physical properties
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Interstitial
Alloying
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Substitutional
Alloying
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Microstructures
Metals composed of grains (crystals)
Very small
Separated by grain boundaries
Different phases within grains
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Microstructure
of Iron
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Iron-Carbon
Phase Diagram
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Phases in Steel
Ferrite
Cementite
Austenite
Bainite
Pearlite
Martensite
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Cooling Rates
Slow - Pearlite - softest
Moderate - Bainite
Fast - Martensite - hardest
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Lamellar Appearance of Pearlite
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Martensite
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Tempering
Restores ductility and toughness and
reduces strength and hardness
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Effects of Tempering
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Temperatures
Alloy is AISI 4142
Tempering temperature
is in degrees F
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Effects of Tempering
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Temperatures
Alloy contains 12% Cr
Note reduction in impact
strength at 885 F (475 C)
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Continuous Cooling
Diagram & Jominy
Hardenability Diagram
for 8630 steel. Phase
formed on cooling
varies with cooling
rate.
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Weld Area & Fe - Fe3C Diagram
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Heat Input
Joules/inch = current x voltage x 60
travel speed (in./min)
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Preheat
Slows cooling rate
Produces less martensite
Reduces risk of cracking
Reduces distortion
Reduces hydrogen
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Carbon Equivalent
Module 8 - 35
( CE )
CE = % C + % Mn + % Ni + % Cr + % Cu + % Mo
6 15 5 13 4
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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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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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Diffusion
Movement of atoms within a solution, be it a
solid, liquid or gas
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Diffusion of Lead and Gold Atoms
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Solubility
Dissolving Salt into Water
Solid into liquid
Diffusion mechanism
Solubility limit
Temperature effects
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Solid Solubility
Unique to metals
Solid into solid
Solubility limit
Temperature effects
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Examples of Solid Solubility
Gold and lead bars
Carburizing
Nitriding
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Stainless Steels
Ferritic
Martensitic
Austenitic
Precipitation Hardening (PH)
Duplex
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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 - 45
Stainless Steel
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Avoiding Sensitization
Heat treatment ( SAWQ )
Stabilized grades
Low carbon grades
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Other Common Alloys
Aluminum
Pure aluminum
Aluminum-copper
Aluminum-magnesium
Copper
Pure copper
Brasses
Bronzes
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