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Sherif A. Mourad
Professor of Steel Structures and Bridges Faculty of Engineering, Cairo University
TOPICS
Basic Metallurgy. Welding Procedure.
COMMON INGOTS
Rimmed Steel (least oxidation). Capped Steel (more uniform core). Killed Steel (complete removing of oxygen). Semi-killed Steel (small amount of deoxidization to kill any rimming action). Vacuum Deoxidized Steel (removal of oxygen without producing nonmetallic incursion)
CLASSIFICATION OF STEEL
CARBON STEEL
Basically an alloy of iron and carbon
Low Carbon (up to 0.15% carbon). Mild Carbon (0.15 to 0.29% carbon). Medium Carbon (0.3 to 0.59% carbon). High Carbon (0.6 to 1.7% carbon).
Most of the production is low and mild, because of their relative strength and ease of welding.
STEEL SPECIFICATIONS
Egyptian Code 260/71. American sources: AISC, AISI, ASTM.
Most commonly used steel in structural works are A36-77 & A242-79. Prefix A is for ferrous metals. 36 & 242 are just index numbers. 77 & 79 are the years the standard was originally adopted.
HEAT TREATMENT
The temperature that the metal is heated, length of time it is held at that temperature, and the rate that it is cooled have an effect on the metals crystalline structure (microstructure). This microstructure determines the properties of the metal. This microstructure can be manipulated by heat treatment.
PREHEAT
Heat from welding disperses through the metal and radiates to the atmosphere causing relatively rapid cooling. Preheating the weldament may slow the rate of cooling of the metal. o Preheat temp. is commonly 330 to 400 F Thick weld metal will require preheat, as the heat is conducted away from the weld zone rapidly as the mass increases.
STRESS RELIEVING
The metal closest to the weld is subject to the highest temperature, which decreases as the distance from the weld zone increases. This nonuniform heat causes nonuniform expansion and contraction. These stresses may be relieved by uniformly heating the structure after it has been welded. Metal is heated to a temperature just below the point where microstructure changes.
HARDENING
Hardness of steel may increase by heating it up to 50oF to 100oF above the temperature that a microstructure change occurs, then placing the metal in a liquid solution that rapidly cools. This rapid cooling (quenching) locks in place microstructures that contribute to hardness. According to the speed they cool the metal, oil is fast, water is faster and salt brine is fastest.
TEMPERING
Tempering takes place usually after quenching. Metal is reheated and held for a length of time to about 1335oF, then cooled at room temperature. Tempering reduces brittleness and produces a balance between high strength and toughness.
ANNEALING
A metal is heated up to 50oF to 100oF above the temperature that a microstructure change occurs, then cooled at a very slow rate (usually in a furnace). The main aim of annealing is to soften steel and create a uniform fine grain structure. Welded parts are seldom annealed as high temperatures may cause distortion.
NORMALIZING
Normalizing is similar to annealing but with a different method of cooling. Normalized steel is cooled in still air, rather than in a furnace.