Hydrogen induced cracking (also referred to as cold cracking), is caused by the

diffusion of hydrogen in the crystal lattice of HAZ near the fusion boundary. A
tomic hydrogen is dispersed throughout the weld material, making it weak in mech
anical properties. The entrapped hydrogen makes cavities in metal that results i
n cracking due to weak ductility and tensile strength. When metal is subjected t
o tensile stress with high level of hydrogen content, hydrogen induced cracking
occurs. Hydrogen cracking is also named as toe cracking or under bead cracking d
ue to its location of occurrence. It primarily occurs in High strength Low alloy
steels. During welding hydrogen is induced due to the moisture and organic comp
ounds by the usage of cold cellulosic electrodes. Proper cleaning of metal surfa
ce and pre-heating are the preventive steps to avoid alarming hydrogen induced c
racking. Below listed are the ways to reduce Hydrogen cracking in welded items.
1. Pre-Heat
Pre-heating is one of the best step to achieve good solidify microstructure as i
t slows down the cooling rate to facilitate solidification. In this way controll
ed cooling provides the desired microstructure that is not prone to hydrogen cra
cking. In worst the rapid cooling may result in sensitive microstructure to HIC
.
2. Interpass Temperature
Welder associates must define the peculiar interpass temperature. Once this temp
erature is specified, the base metal must be pre-heated to that temperature befo
re depositing the other weld pass. In this way cooling rate is controlled and th
e mechanical properties of both weld metal and HAZ are secured, avoiding hydroge
n cracking.
3. Post-Heat
After welding is finished, apply post heat to eliminate any remaining hydrogen.
On post weld heating, the metal gives off the hydrogen that lessens the risk of
hydrogen induced cracking. Moreover post weld heattreatment (PWHT) is also appli
ed for the removal of harmful residual stresses, in order to achieve the desired
microstructure as per requirement of service.
Also see the usefulness of Post Weld Heat Treatments.
4. Suitable arc process
Metals that are prone to hydrogen cracking must not be welded by those arc proce
sses that induce hydrogen in the weld metal. MIG welding with surface tension te
chnology is the recommended process for welding of high strength low alloy steel
s, rather than applying stick welding with cellulosic electrodes. In latter case
high diffusion of hydrogen occurs that leads to serious cracking in steels.
5. Suitable filler metal
As mentioned above cellulosic stick electrodes are the mean of hydrogen embrittl
ement. Moisture and the organic compounds are the source of hydrogen. Such elect
rodes provide hydrogen gas shielding. For this, basic electrodes (minerals like
calcium and magnesium carbonates) are available that give low hydrogen shielding
, reducing the risk of cracking in low alloy steels.
6. Multipass technique
Multipass method renders tempering effect, modulating the microstructure in orde
r to get rid of hydrogen content. Every next pass tempers the previous deposit p
ass and protects it from cracking. On the other hand hot pass is also applied fo
r same purpose. We know hot pass is used to clean the root pass by the removal o
f slag content. Moreover it is also applied to render heat treatment effect so t
hat root may not be subjected to hydrogen cracking.
7. Temper bead technique
Temper bead technique is introduced to provide the heat treatment effect in repa

ir welds where post weld heat treatment is difficult. In this technique overlapp
ing of beads, assists the self-heat treatment that refines the course grain zone
s, due to which desired microstructure with improved properties in both weld met
al and HAZ, is obtained. Furthermore it also minimizes the residual tensile stre
sses. All these features encourage the reduction of hydrogen induced cracking.
8. Shielding gases
As it is stated above cellulosic electrodes offer hydrogen gas shielding. For th
is moist free (low hydrogen) shielding gas must be used in case of metals that a
re prone to hydrogen cracking. Use of baked electrodes, is the recommended pract
ice in order to lower the hydrogen content.
9. Rust and scale removal
Before welding, cleaning of joint with removal of rust and scale, is always endo
rsed. Since the presence of moisture or grease on parent metal, is the major sou
rce of hydrogen. So making the joint rust free and proper cleaning are the param
ount activities before the commencement of weld.
10. Fusion
Perfect fusion is achieved by the merging the weld metal at weld toes, to provid
e reinforcement. As stress concentration is one of the cause for hydrogen cracki
ng/toe cracking. Reinforcement at weld toes reduces the stress concentration and
thus avoiding the toe cracking.
Comments
In brief residual stresses, high hydrogen content and sensitive micro structure
are the primary causes for hydrogen cracking. Control of these elements gives a
cracking free weld. In order to achieve quality welds, following practices must
be exercised;
Proper cleaning of joint
Pre-heating of joint
Use of nickel and austenitic filler materials
Use multi-pass method in case of those weldable materials that are sensitive
to HIC.