Nitin Vikas

Weld HAZ microstructure

Himanshu Tiwari
The Metallurgy of Welding

Encompasses:
Melting
Solidification
Gas-metal reactions
Slag-metal reactions
Surface phenomena
Solid state reactions
Weld includes melted zone (fusion zone)

and the region around it (HAZ)

Chemistry can be controlled by choosing appropriate filler material

But, microstructure can be vastly different than base material

1. Weld metal
Microstructure and mechanical properties are affected by;

Reactions of the metal with gases in the vicinity

Reaction with nonmetallic liquid phases

Solid state reactions occurring in the weld after solidification

1.1 Solidification
Nucleation may occur;
at the liq-solid interface (fusion boundary) or
from foreign solid particle suspended in the
liquid

Growth columnar grains or dendrites

Grains are long and parallel to heat flow

Solidification defect ingotism can occur

Columnar grains growing from opposite sides
meet at the mid-plane of the weld
1.1
Formation of dendrites result in microsegregation

Dendrites are of a higher melting composition than the

interdendritic material

Dendrite spacing depends on

solidification rate (controlled by energy
input)

More rapid the solidification the more

closely spaced are the dendrites
1.2 Gas-metal reactions
Liquid metal transfer across the arc in the form
of tiny droplets (offers large reacting surface
area)
Also, superheated to temperatures far above
melting point

Arc atmosphere is highly reactive by ionization

of gas molecule
Ex. nitorgen, oxygen, hydrogen and water
molecule
Sources of oxygen are
Arc atmosphere
Oxide or scale on the surfaces of W/P
Already present in the metal
1.2
Control of oxygen is critical in
welding of steel
To avoid reaction between C and O
C + O CO (gas bubble - porosity)

Can be prevented by

Adding deoxidizing elements having high affinity for oxygen

Al, Si, Mn
Si + 2O SiO2
2Al + 3O Al2O3
Mn + O MnO Product is nonmetallic inclusions
1.2
Source of Deoxidizer
are available as constituent of flux

Amount of deoxidizer is decided by process variable

For eg
For 100% CO2 atmosphere (strongly oxidizing)
Large quantity of deoxidizer will be needed

If the atmosphere is of argon, far less deoxidizer is needed

Flux for a given process must be selected with care

or else under-deoxidation / over-deoxidation may happen

Porosity Loss of ductility and toughness

Water vapour

Is source of hydrogen which can cause porosity

and embrittlement

Can be controlled by ensuring molten metal has sufficient fluidity

to allow the gas to escape

Care should be taken to heat electrode before welding

 1.3 Liquid -metal reactions
Slag (non metallic liquid phases) formed, interact with liquid metal

Form by melting of flux

Designed to absorb nonmetallic deoxidation products

Remove sulphur and phosphorus

Help in preventing hot cracks

In steel Mn is added to take care of sulphur

by forming MnS
1.4 Solid state reactions
Related to phase transformation in solidified metal (specially
steels)

If transformation result in formation of hard and brittle phase then

cold cracks (delayed cracking) may occur

Presence of hydrogen in solid state aid in cracking

Can be avoided by preheating

Excluding hydrogen from the immediate environment
2. Heat Affected Zone (HAZ)
Depends on:
Welding process / variables
Material

Four types of material

1. Solid solution strengthened
2. Alloy strengthen by cold working
3. Alloys - Precipitation hardened
4. Alloys Transformation hardened
2.1 Solid solution strengthened
Easiest to weld
Grain growth may occur in the region close to fusion line

Example:
Al alloys (non heat-treatable)
Cu alloys
Low carbon steel
Stainless steels (ferritic and austenitic)
In austenitic SS HAZ - sensitization occur

High Cr (>11 wt%) for good corrosion resistance

For HAZ in temperature range of 550-650oC Cr combines with C
to form chromium carbide
This precipitation reduce Cr content to level susceptible to
corrosion and the region is said to be sensitized
Remedies
Low C stainless steel
Add elements which can combine with C (Ti)
Reheat welded part to 980oC and cool it rapidly to room
temperature

Dissolve already formed chromium carbide and avoiding

reformation of it
2.2 Strain hardened material
Typical variation in microstructure and mechanical properties in
work hardened material and after annealing
2.2 Strain hardened material
In HAZ recrystallization will happen
Brings down strength
Alloy without phase change

A Cold worked metal

B RXZ metal Alloy with phase change - steel
C Weld metal
 a) b) c) d)

https://www.llnl.gov/str/November01/Elmer.html

Microstructure of titanium after welding:

a) the base metal,
b) the small-grained portion of the HAZ where the gamma phase
has partially transformed to the beta phase,
c) the large-grained portion of the HAZ where gamma-phase
titanium has fully transformed into the beta phase
d) the fusion zone.
2.3 Precipitation hardened material
Precipitation sequence Ageing behavior

Peak aged
Overageing
2.3 Precipitation hardened material
Influence of weld thermal cycle on precipitation hardening alloy
2.4 Transformation hardened material

Martensite in steel is very hard

phase (and brittle)

To make it ductile tempering

treatment is given sacrificing
hardness in the process
2.4 Transformation hardened material
1. Next to fusion line heated
0.3% C steel
close to MP (austenite region)
extremely coarse grain
transforms to martensite high Peak
hardness temperature

2. Heated to all austenite region

fine grained difficult to
transform to martensite
moderate hardness
3. Intercritical zone austenite-
ferrite mixture martensite may
form not very hard
4. Tempered zone
2.4 Transformation hardened material
Weld zone hardness

Weld bead on 25 mm
0.25% C steel
http://www.thefabricator.com/article/tubepipeproduction/laser-welding-of-stainless-pressure-tubes
http://www.weldreality.com/SHIP%20YARD%20DATA.htm