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Experiences with HAZ Cold Cracking

Tests on a C-Mn Structural Steel

Significant details of the controlled thermal severity


(CTS) test are compared with those of the Tekken Y-
groove test

BY W. P. CAMPBELL

ABSTRACT. The heat-affected zone p r o p e n s i t y to heat-affected zone and the Y-groove specimens. It was
cold cracking tendency of a C-Mn cracking. hoped that this study would contrib-
structural steel was evaluated using It was shown that special proce- ute to more accurate and realistic
controlled thermal severity (CTS) and dures are necessary in order to con- evaluation of w e l d a b i l i t y behavior
Tekken Y-groove specimens. This trol the critical root opening in the based upon small scale welding tests.
permitted a comparison of the per- Y-groove specimen. One method is to
formance of the single-pass fillet weld use e l e c t r o - d i s c h a r g e machining
E x p e r i m e n t a l Details
test and the single-pass butt weld test (EDM) to make the root opening in a
and the development of improved u n - one piece specimen. However,this has Materials
derstanding of the performance of the the disadvantage that metallurgical
latter. effects of the EDM process upon the All steel used in the study was from
No cracking occurred in the CTS cut surface of the o p e n i n g may the same heat and rolled to a thick-
tests but severe weld or heat-af- possibly influence crack initiation. A ness of either 1 in. (25 mm) or 1-1/2
fected zone cracking was encoun- better method is to employ a two in. (38 mm). The plate compositions
tered in the Y-groove tests under c o n - piece specimen which has wide root were determined to be as given in
ditions which had been expected to faces in the restraint portions. When Table 1.
be less likely to produce cracking these faces are in contact, the cor-
than the conditions employed in the rect root opening is maintained in the Electrodes
CTS tests. test weld portion after welding the
restraint portions. All welding was performed using
With the thickest plate tested, i.e.,
5/32 in. (4 mm) E7018 classification
1-1/2 in. (38 mm), severe weld metal
electrodes from one manufacturer
cracking occurred when the restraint
and lot. The moisture content of the
level in the Y-groove test was at a
Introduction covering was monitored at intervals
m a x i m u m , r e g a r d l e s s of the root
during the program using the proce-
opening in the range of 0.04-0.08 in. The tendency of steels to heat-af- d u r e specified in CSA S t a n d a r d
(1-2 mm). When the restraint level fected zone cold cracking may be as- W48.1-1969. All test welds were de-
was reduced by relief slots, weld sessed by the performance of the posited with e l e c t r o d e s having a
metal cracking was replaced by se- steels in single-pass, fillet welded c o v e r i n g m o i s t u r e c o n t e n t in the
vere heat-affected zone cracking. specimens as employed in the C o n - range 0.4 to 0.6%.
With 1 in. (25 mm) plate, only weld trolled Thermal Severity (CTS) test.
metal cracking occurred when the This has been used extensively in
root opening was 0.02 in. (0.5 mm) Test Procedure and Results
many countries. The cracking t e n -
and only heat-affected zone cracking dency may also be evaluated in
occurred when the root opening was CTS Tests on 1 in. (25 mm) Plate
single-pass butt welded specimens as
0.08 in. (2 mm). Thus certain optimum employed in the Y-groove Tekken Single-pass fillet weld tests C1-C4
conditions were indicated in order to test. This has been used primarily in inclusive were made using the CTS
u t i l i z e the test for s t u d y i n g t h e Japan, where it was developed, but its specimen shown in Fig. 1. Both top
use appears to be increasing in other and b o t t o m m e m b e r s were m a -
countries. chined from the 1 in. (25 mm) plate.
In order to gain experience with The anchor welds were deposited first
W. P. CAMPBELL is Research Scientist,
Welding Section, in the Physical Metal- and to evaluate the Y-groove test, it at a higher level of energy input than
lurgy Research Laboratories of the De- was decided to undertake compara- that of 30-36 k J / i n . (1.2-1.4 k J / m m )
partment of Energy. Mines and Re- tive studies of the cracking tendency which was used for depositing the two
sources. Ottawa, Ontario K1A-OG1 of single-pass welds in a commonly test welds. Each test weld was de-
Canada. used structural steel with both CTS p o s i t e d w i t h the s p e c i m e n at a

WELDING RESEARCH SUPPLEMENT! 135-8


Table 1 — Composition of Steel Tested, Wt. %

Total
CE(a,
C Mn Si S P Al N

1 in. (25 m m ) plate 0.22 1.32 0.20 0.021 0.006 0.025 0.005 0.44
11/2 in. (38 mm) plate 0.19 1.27 0.20 0.022 0.006 0.016 0.005 0.40

(a) Carbon-equivalent = %C + % Mn/6

temperature of about 70 F (21 C), and Cm


the second weld was made 2 h after
the first. Tests CC1 and CC2 were
similar except that the specimens
were 8 in. (203 mm) rather than 4 in.
(102 mm) wide, i.e., the test welds
were 8 in. (203 m m ) l o n g . Each
specimen had two anchor bolts. Tests
C5 and C6 were similar to C1-C4 in-
clusive, except that the specimens
were stiffened by the addition of a
1 X 4 X 1 2 in. (25X102X305 mm) plate,
positioned at right angles to the bot-
tom plate at a central longitudinal
location, and d o u b l e - f i l l e t w e l d e d
along the c o m m o n 12 in. (305 mm)
dimension to f o r m a T-shaped bot-
TEST WELD-TRITHERMAL-
tom assembly. These modifications to HEAT FLOW
the "standard" CTS specimen were
made in attempting to increase the
cracking severity of the CTS test.
At least 48 h from completion of BOTTOM PLATE
welding, each test weld was sec-
tioned transversely, using a liquid
cooled abrasive cut-off wheel, at three
equally spaced locations along the
r|in. DRILL FOR £in. DIA BOLT h*.i±* 4in.STEEL SHIM PLATE
length. All six surfaces thus exposed
in each test weld were inspected for (14mm) (13mm) (2 x 89x 102 mm)
cracking under ultraviolet lighting CONTROLLED THERMAL SEVERITY (CTS) SPECIMEN
after magnetization while flowing a
liquid containing fluorescent mag- Fig. 1 — Controlled thermal severity (CTS) weldability specimens, used for 1 in. f25 mm)
netic powder over the surfaces. No plate
cracking was found in any of the test
welds.

Y-Groove Butt Weld Tests on


1 1/2 in. (38 mm) Plate ing occurred when the opening was cept Y15 and Y16, are given in Table
Single-pass butt weld tests (Table 0.08 in. (2 mm) wide and that crack- 2.
2) were made in the 1-1/2 in. (38 mm) ing was reduced almost to zero when Measurements for Y15 and Y16
plate using Y-groove specimens in- the opening was either reduced or in- could not be obtained because these
tended to conform to either Fig. 2, 3 or creased by approximately 0.02 in. (0.6 specimens had been prepared for ex-
5. The root opening* in specimens to mm). It was further noted in this paper amination at least 48 h after comple-
Fig. 3 were made using electro-dis- that a Japanese Industrial Standard tion of welding, first by heating them
charge machining (EDM). on the Tekken test had specified the in an oven for 1 h at 750 F (399 C) to
While welding the restraint welds in opening to be 0.079 ± 0.008 in. (2 ± oxidize any cracks and then by break-
the two piece specimen (Fig. 2), a 0.2 mm). However, in the Japanese ing the welds open, after cutting off
steel shim plate, 0.08 in. (2 m m ) thick, publications which had been examin- the restraint p o r t i o n s , to p e r m i t
was inserted in the test weld portion ed prior to commencing our project, observation of the extent of oxidized,
of the specimen and was removed be- there had been no reference to root cracked areas.
fore depositing the test weld. opening tolerances nor to the In all of the other tests, after at least
Somewhat later in the study, an Japanese standard. 48 h from completion of welding, the
Australian paper (Ref. 1) was noted in In view of the apparent importance specimens were cut transversely at
which attention was drawn to the c r i - of the root opening dimension, the intervals of approximately 1/2 in. (13
tical nature of the width of the root transverse sections from the mm), using a liquid cooled abrasive
opening. According to this study, the specimens which were intended to cut-off wheel, and all ten surfaces
root opening should be held in the conform to either of Fig. 2 or 3 were from each weld were examined by the
range 0.079 ±0.004 in. (2.0 ± 0 . 1 mm). subsequently re-examined, not for magnetic particle process as for the
It was reported that m a x i m u m crack- cracking as in the original examina- CTS specimens. As shown by Table 2,
tion, but to determine the root o p e n - the root openings had not been main-
"Referred to as gap width in Figs. 2, 3 and ing. The measurements for the root tained within the r e c o m m e n d e d range
4. opening, representative of all tests ex- when using the two piece specimens,

136-8 I M A Y 1976
intended to conform to Fig. 2. Typical- clamped together in preparation for least 3*00 F (249 C). This was the toler-
ly, the root openings were of the order making the anchor welds, was 0.080 ance recommended by the Aus-
of 0.04 in. (1 mm). In contrast, the root + 0.003-0.001 in. (2+0.08-0.03 mm). tralian researchers (Ref. 1). The
o p e n i n g s for the one piece Thus the opening just before making modified workshop drawing is shown
specimens, intended to conform to the test weld should always be in the in Fig. 5.
Fig. 3, were within the recommended range 0.079 ±0.004 (2.0 ±0.1 mm) In tests Y5, Y6, Y15, Y16, Y24 and
range. with or without preheating up to at Y25 (Table 2), a series of parallel slots
Near the completion of the study,
tests YA and YB were made using a
5.9in
two piece modified specimen. In Fig. (I50mm)
5.9 in.
(I50mm)
2, the joint for the restraint welds has
a chisel edge, i.e., no root face. In
H
t— SAW CUT DEPTHS 1 — p—SAV CUT DEPTHS
specimens YA and YB, the joints for
the restraint welds were machined to
have a root face equal to 1/3 of the
-4
A
I.. c\; , ' Q UJ T-

plate thickness. Additionally, the joint o


for the test weld portion was modified UJ •]s»
2
so that when the specimens were — A A
clamped together with the root faces B p
UJ
in
of the restraint weld portions in con- -4
tact, the 0.08 in. (2 mm) opening was
automatically provided in the test por- " ll
Tiff —
CD

z>
tion. Similar joint preparations were
i
.^v--Js_.
j i ;
1
shown in a Japanese publication (Ref. E 6 I
3) but no explanation was given for
their use.
t- in

3h
i

i ;!
i l

Experiments by the author with this i_JdaL_


modified specimen indicated that,
even with the relatively heavy root -RESTRAINT WELD

faces in the restraint weld portions,


the root opening at the test weld por-
tion was reduced by about 0.004 in.
(0.1 mm) after the anchor welds had
cooled to room temperature. Preheat- ENLARGED SECTION A -A ..GAP WIDTH
ing the specimen to about 300 F (149 . 0 8 in. (2 mm)
ENLARGED SECTION B - 8 ENLARGED SECTION A - A
C) caused expansion of the root * DEPTH OF RESTRAINT RELIEVING SAW CUTS = 0 * DEPTH OF RESTRAINT RELIEVING SAW CUTS = O
opening by about 0.004 in. (0.1 mm). FOR FULL RESTRAINT, OR SPECIFIED SEPARATELY FOR FULL RESTRAINT, OR SPECIFIED SEPARATELY
Consequently the workshop draw- WHEN REDUCED RESTRAINT IS EMPLOYED WHEN REDUCED RESTRAINT IS EMPLOYED

ings were modified so that the open- Fig. 2 — Two piece Y-groove weldability Fig. 3 — One piece Y-groove weldability
ing, when the specimens were specimen used for 1-1/2 in. (38 mm) plate specimen used for 1-1/2 in. (38 mm) plate

(a)
Table 2 — Y-Groove Tests on 1-1/2 in. (38 mm) Plate

Initial Root'"' Root crack Other type


Test Test Restraint Temp. opening length — % of cracks — % of
no. specimen condition F(C) in. (mm) weld depth weld depth

Y1 Fig. 2 Full 70(21) 0.04(1) 20-60 None


Y2 Fig. 2 Full 70(21) 0.04(1) 20-70 None
Y3 Fig. 2 Full 70(21) 0.04-0.07 20-80 Toe cracks — see Fig. 6
(1-1.8) (Fig. 6)
Y7 Fig. 2 Full 70(21) 0.04(1) None HAZ cracks — see Fig. 9
Y8 Fig. 2 Full 70(21) 0.06 (1.5) 30-50 HAZ cracks extending
30% from root and
30 to 8 0 % f r o m toe
Y4 Fig. 3 Full 70(21) 0.08 (2) 60-100 None
(Fig. 8)
Y15 Fig. 3 0.79-in. 70(21) Not measured < c > 50-100 HAZ cracks extending
(20-mm) but more probably 50-100% from root
slots 0.08 (2)
Y16 Fig. 3 70(21) 25-40 HAZ cracks extending
25-40% from root
Y5 Fig. 3 1.6-in. 70(21) 0.08 (2) None HAZ cracks extending
(40-mm) 20-90% from root —
slots see Fig. 7
Y6 Fig. 3 70(21) 0.08(2) None HAZ cracks extending
20-50% from root
Y24 Fig. 3 " 200 (93) 0.08(2) None None
Y25 Fig. 3 " 200(93) 0.08 (2) None None
YA Fig. 5 Full 300(149) 0.08(2) None None
YB Fig. 5 Full 300(149) 0.08 (2) None None

(a) Energy i n p u t w a s held c o n s t a n t at 4 0 - 4 3 k J / i n . (1.6-1.7 k J / m m )


(b) M e a s u r e m e n t s m a d e o n t r a n s v e r s e s e c t i o n s
(c) C r a c k s w e r e o x i d i z e d by h e a t i n g s p e c i m e n s in a f u r n a c e a n d w e l d s w e r e b r o k e n a p a r t f o r visual e x a m i n a t i o n .

W E L D I N G R E S E A R C H S U P P L E M E N T ! 137-8
either 0.79 in. (20 mm) or 1.6 in. (40 depth of 1.6 in. (40 mm). Y-Groove Butt Weld Tests on
mm) in length were cut from the 8 in. Preheating, used in tests Y24, Y25, 1 in. (25 mm) Plate
(203 mm) edges of the specimens, in YA and YB, was achieved by heating
Before it was realized that the root
the manner illustrated in Fig. 2 or 3. the specimens for at least one hour
opening in the two piece specimen
These slots provided a reduction in per inch of plate thickness in an oven
was not being maintained in the rec-
t h e r e s t r a i n t as c o m p a r e d t o set at the desired temperature. Test
o m m e n d e d range, several tests
s p e c i m e n s c o n t a i n i n g no s l o t s . welds were c o m m e n c e d within a few
(Table 3) were made, with specimens
Reduction of restraint was greatest seconds after the specimens were re-
intended to conform to Fig. 2, on 1 in.
with the specimens having a slot moved from the oven.
(25 mm) plate using the steel shim
plate, 0.08 in. (2 mm) thick, to set the
a
Table 3 — Y-Groove Tests on 1 in (25 mm) Plate< > root opening in the test weld por-
tions. Other details of the test proce-
Energy Root < b | Root crack dure were as employed in the tests on
Test Restraint input opening, length — % of 1-1/2 in. (38 mm) plate and as shown
no. condition kJ/in. (kJ/mm) in. (mm) welddepth,c) in Table 3. All specimens were ex-
amined for cracking by magnetic par-
ticle testing of transverse sections as
Y9 Full 41-42 0.02(0.5) 30 max
was used for all of the CTS specimens
(1.6-1.7)
0.02(0.5) 30 max
and most of the Y-groove specimens
Y10 Full
Y11 0.79-in. 0.02-0.04 None in 1-1/2 in. (38 mm) plate.
(20-mm) (0.5-1) After data were found concerning
slots the r e c o m m e n d e d tolerance on the
20 max
Y12 " 0.02-0.03 None
root opening, measurements of the
Y13 1.6-in. opening were made (Table 3) on the
(40-mm) (0.5-0.8)
transverse sections as had been done
slots
None for the specimens in the 1-1/2 in. (38
Y14 " " 30 max mm) plate.
Y17 " 33(1.3) " 30 max Three specimens in 1 in. (25 mm)
Y18
plate were also prepared similar to
(a) Initial plate temperature 70 F (21 C) Fig. 2 except for additional machin-
(b) Measurements made on transverse sections ing in the test weld location on the
(c) No other type of cracking occurred
plate having the single bevel prepara-
tion. An additional 0.08 in. (2 mm)
5.9 ii>. 5 . 9 in. thickness of metal was removed from
(150 mm) (150 mm) the bevel face so that when the two
chisel edged "noses" of the anchor
weld joint preparation were in con-
tact, a root opening of 0.08 in. (2 mm)

i
1
i was obtained in the test region. How-
ever, when the anchor welds were

tj
completed, it was found that the
',, " *-E sy " ^. opening at the test weld had been re-
duced well below the desired toler-
l.9in.

E
cn E 1 E ance. It was not until later in the study
>mm)

00
c 1 ~ c E B CO that a further modification of this idea
CO
CO a* O was employed as exemplified by tests
r<S
E
$
| % K O r<i fc YA and YB (Table 2).
A A £ B B
Experience with the Y-groove test
L 4 i i- 4 to this point had shown that it was dif-
A>_ f ficult in the two piece assembly to
control the root opening with the ac-
curacy indicated by the Australian
study (Ref. 1) to be necessary. In con-
trast, no difficulty was experienced in
' maintaining the 0.08 in. (2 mm) open-
ing when it was made by the EDM
,62in. process in a one piece specimen,
D I A - 2 HOLES DIA-2 HOLES
(16mm) such as that shown in Fig. 3, and in
the 1-1/2 in. (38 mm) plate. Also at this
time, it was noted that other research
60°,
V"7 (Ref. 2) had indicated that more
severe test conditions could result if a
straight rather than an angled root
o p e n i n g w a s e m p l o y e d in t h e
specimen.

<
GAP WIDTH
,08in. (2mm)
GAP WIDTH
.08in. (2mm)
IL Consequently, another series of
tests (Table 4) on 1 in. (25 mm) plate
was u n d e r t a k e n w i t h o n e p i e c e
ENLARGED SECTION A - A ENLARGED SECTION B - B specimens having either straight or
angled root openings produced by
ANGLED - GAP SPECIMEN STRAIGHT-GAP SPECIMEN
the EDM process (Fig. 4). Prior to
Fig. 4 — One piece Y-groove weldability specimens used tor 1 in. (25 mm) plate welding, the width of the root open-

138-8 | MAY 1976


ing was checked with a feeler gage that shown in this Figure. In these All other tests summarized in Table
and in all specimens was found to specimens, weld cracking pre- 2 were made using specimens which
conform to the limits 0.079 ±0.004 in. dominated, with some toe crack- permitted control of the root opening
(2.0 ±0.1 mm). No preheating was ing occurring in tests Y3 and Y8 and within the r e c o m m e n d e d range of
employed and all specimens p r o - some heat-affected zone cracking ini- 0.079 ±0.004 in. (2 ± 0 . 1 mm). Only
vided full restraint. Examination for tiating from the root in test Y8. Only severe weld metal cracking occurred
cracking was performed by the mag- the latter form of cracking occurred in in test Y4 under full restraint condi-
netic particle method as in previous test Y7. tions. Cracking appeared to be some-
tests. Measurements (Table 4) were
also made on the transverse sections
to recheck on the root opening width. Table 4 — Y-Groove Tests on 1 in. (25 mm) Plate with Root Opening
Made by Electro-Discharge Machining (EDM)
Auxiliary Tests on
Transverse Sections
Root Energy Initial HAZ crack
Occasionally, it was not possible to Test opening input temp.. length-% of
determine from the magnetic particle no. (Fig.4)(b) k J / i n . ( k J / m m ; F(C) weld d e p t h l c )
examination whether cracking was in
YY1 Angled 35(1.4) 70(21) 25-50 (Fig. 9)
the weld or in the heat-affected zone.
YY2 Angled 32(1.3) 70(21) 40
In these cases, metallographic ex- YY3 Straight 32(1.3) 70(21) 50-75
amination was undertaken in order to YY4 Straight 32(1.3) 70(21) To 100 (Fig. 10)
ascertain the location of the cracks. YY11 Straight 30(1.2) 70(21) 50-90
Macrophotographs were prepared YY12 Straight 30(1.2) 70(21) Up to 100
(Figs. 6-10) to illustrate the types of YY5 Straight 32(1.3) 200(93) None
cracking observed. Figure 11 shows a YY6 Straight 32(1.3) 200(93) None
typical heat-affected zone crack at YY7 Angled 31 (1.2) 200(93) None
higher magnification. YY8 Angled 31 (1.2) 200(93) None
YY9 Angled 40(1.6) 70(21) 25-40
Metallographic examination was 25-40
YY10 Angled 43(1.7) 70(21)
made on a section from test YY1
(Table 4) in order to assess the metal-
(a) All specimens were under full restraint.
lurgical effect of the EDM process
{bl All root openings were 0.08 in. (2.0 mm) measured on transverse section.
upon the steel adjacent to the weld (c) Cracks initiated at the root of weld, propagated upwards in the HAZ and in some cases changed direction to ter-
root. Very small, metallurgically minate in the weld No other weld cracking occurred.
altered areas were noted inter-
mittently along the cut edge of the
root opening preparation (Fig. 12).
Where these areas were located in the
heat-affected zone of the test weld,
there was evidence of coarse marten-
-8" rnvrsit"""'
site formation (Fig. 13).
Microhardness tests were made on
representative sections of various test
welds. The results, summarized in
Table 6, were obtained using a Tukon
testing m a c h i n e with a d i a m o n d
pyramid indenter and a 10 kg load.

Discussion
In the CTS tests, each test weld
provided "trithermal" heat flow condi-
tions and thus the " c o m b i n e d plate
thickness" at the test welds was al-
ways 3 in. (76 mm). No cracking of
any kind was f o u n d in any of the
specimens despite attempts to in-
crease test severity by either doubling
the sample width (tests CC1 and CC2)
or by increasing the rigidity of the bot-
tom plate (tests C5 and C6). The use
of an opening at the root of the test
weld, in all of the specimens, is known
to increase the cracking tendency.
Consequently the absence of any
cracking in this series of tests sug- T A • C 0

gests that little difficulty would be ex- I ) DEPTH Of RESTRAINT RELIEVING SAW CUTS - 0 ja MM ta. MM l
1 •M hi mm rw
FOA FULL RESTRAINT, Oft SPECIFIED S E M t M T E L Y
pected in practical fillet welded joints. WHEN REDUCED RESTRAINT tS EMPLOYED-. i *Z.7 09« 2.90
. 171 4 . 3 4
192 4 . M
7.34
3 . 0 M 71.11
3.17 1 80.34
0 7 * 2,01
K)2 2 3 9
i 190 209

It is evident from tests Y 1 , Y2, Y3 i 23.4 .242 LIB .3*9 9.79 3.242 • 2 . 3 5 123 3 . 1 2

and Y8 (Table 2) that severe cracking 4 3ft. 1 M7 9.§3 STt I4.W 3 317 M . 0 3 169 4 . i »

can occur in fully restrained Y-groove 4 4*4 . 4 0 * II. M • 7 4 17.12 3.4W • 7JK .196 4 7 2

z 90. • . 5 3 1 13.49 ,7TO 19.3* 3931 89.69 20* 3 2 3


weldability specimens intended to
conform with Fig. 2 but, in fact, hav- Fig. 5 — Modified two piece Y-groove weldability specimen showing dimensions required
ing a root opening only about one half for machining each piece

WELDING RESEARCH SUPPLEMENT! 139-8


what more servere than in tests in. (20 mm) slots had no major in- tests Y5 and Y6. In these tests, only
Y1, Y2, Y3 and Y8. Because severe fluence. continuous, severe heat-affected
cracking, apparently with weld crack- However, with still further reduc- zone cracking was found, initiating
ing predominating, also occurred in tion in restraint due to the 1.6 in. (40 from the root of the joint. The results
tests Y15 and Y16, it is evident that the mm) slots, a marked change was ob- indicate that, under the higher condi-
reduction in restraint due to the 0.79 served in the nature of cracking in tions of restraint, as in test Y4, weld
metal cracking usually occurs and
thus precludes or inhibits heat-af-
Table 5 — Summary of Microhardness Test Data a) fected zone cracking by reducing the
stresses imposed upon the heat-af-
fected zone. With much lower re-
Sections Refer- Combined plate Energy input Vickers , b ) straints, as in tests Y5 and Y6, the
from ence thickness kJ/in. (10 kg load)
weld cools without cracking through
test no. Table no. in. (mm) (kJ/mm) DPN
the temperature range which favors
CC1.CC2 See text 2 (51) 30-36 211-250 weld cracking but the stresses im-
(1.2-1.4) (387-442) posed upon the heat-affected zone in
Y5.Y6 2 3 (76) 40-43 222-228 the cold cracking temperature range
(1.6-1.7) (345-390) are still sufficiently high to contribute
Y24, Y25 2 3 (76) 40-43 196-218 to this form of cracking.
(1.6-1.7) (312-382)
Y11, Y12 3 2 (51) 41 - 4 2 209-213 As shown by tests Y24 and Y25,
(1.6-1.7) (294-363) preheating to 200 F (93 C) is suf-
Y17, Y18 3 2 (51) 33 (1.3) 190-211 ficient to prevent such cracking. In
(330-390) tests YA and YB, preheating to 300 F
YY11, YY12 4 2 (51) 30 (1.2) 232-237 (149 C) prevented cracking in
(315-374) specimens providing the maximum
YY9, YY10 4 2 (51) 40-43 205-232 restraint. Judging from tests Y1, Y2,
(1.6-1.7) (307-372)
Y3, Y4, Y7 and Y8, this level of
preheating has prevented, in tests YA
(a) All specimens were welded at room temperature, i.e.. 70 F (21 C). and YB, all forms of cracking such as
(b) Areas tested were the weld metal and the HAZ very close to the fusion line. Numbers without parentheses are for weld
metal; numbers in parentheses are for HAZ values. were encountered in the former tests.

Fig. 6 — HAZ toe and weld metal cracks (Test Y3 — Table 2). X8, Fig. 8 — Weld metal crack (Test Y4 — Table 2). X8, reduced 16%
reduced 17%

Fig. 7 — HAZ crack from root deflecting into weld (Test Y5


Table 2). X8, reduced 18%. HAZ crack (Test YY1 — 7ab/e 4). X8, reduced 16%

140-8 I MAY 1976


Fig. 12 — Remelted areas on surface of root opening made by the
EDM procedure in Y-groove specimen, remote from test weld
(Test YY1 — Table 4). X600, reduced 26%
Fig. 10 — HAZ crack (Test YY4 — Table 4). X8, reduced 20%

Fig. 13 — Remelted area on surface of root opening made by the


EDM procedure in Y-groove specimen, very close to test weld
(Test YY1 — Table 4). X600, reduced 37%

Fig. 11 — Microstructure and crack in HAZ ot Y-groove specimen


(Test YY1 — Table 4). X200, reduced 23%

Possibly some temperature inter- ence in cracking behavior in the two as restraint increases with the plate
mediate between 200 F (93 C) and 300 types of specimens, it must be con- thickness.
F (149 C) would also have been as cluded that the level of stress, in the In tests Y13 and Y14, the further
effective. root area, developed by the spec- lessening of restraint by still deeper
Certain factors should be con- imens is a chief reason for the dif- slots, caused complete elimination of
sidered when comparing the exten- ference. Even with the deepest slots weld metal cracking. Thus it seemed
sive cracking in the Y-groove tests on employed, i.e., 1.6 in. (40 mm), probable that, with the elimination of
1-1/2 in. (38 mm) plate with the ab- the stress level in this area of the 1-1/2 weld metal cracking, some heat-af-
sence of cracking in the CTS tests on in. (38 mm) Y-groove specimen must fected zone cracking would then oc-
1 in. (25 mm) plate. In both tests, the be greater than that of the 1 in. (25 cur as was the case with tests (Y5, Y6,
"combined plate thickness" was the mm) CTS specimen. Table 2) on the 1-1/2 in. (36 mm)
same. However, the energy input level In the Y-groove tests on 1 in. (25 plate. A probable, partial explanation
was lower in the CTS tests than in the mm) plate, Table 3 shows that weld for the absence of heat-affected zone
Y-groove tests and the carbon- metal cracking, extending from the cracking in tests Y11, Y13 and Y14 is
equivalent of the steel in the CTS tests root, was the only form of cracking that the root opening was too narrow
was higher than that of the thicker encountered. The root opening in all and thus, based on the Australian re-
plate in the Y-groove tests. These two of these tests was significantly less search (Ref. 1), inhibited crack initia-
factors would be expected to result in than that which had been intended. tion in the heat-affected zone.
a greater tendency for cracking in the With an energy input of 41-42 kJ/in. Another factor is that the greater
CTS tests because of the develop- (1.6-1.7 kJ/mm), moderate weld cooling rates resulting from the
ment of more crack-susceptible m e t a l c r a c k i n g o c c u r r e d in greater "combined plate thickness" in
microstructures in the heat-affected specimens providing full restraint tests Y5 and Y6 could have resulted in
zone. The hardness data in Table 5 (tests Y9 and Y10) and there was evi- more crack sensitive, heat-affected
support this view. Considerably dence of reduction in cracking in tests zone microstructures than in tests
higher hardness values were found in Y11 and Y12 which provided some Y11, Y13 and Y14 despite the differ-
the heat-affected zone very close to reduction in restraint. It is noted also ences in plate carbon-equivalents.
the weld in the CTS specimens, as that cracking was considerably more The development of more crack sen-
compared with hardness values at severe in similar tests (i.e., Y15 and sitive, heat-affected zone microstruc-
corresponding locations in butt weld Y16, Table 2) on the 1-1/2 in. (38 mm) tures in tests Y5 and Y6 is indicated
specimens. Because of the differ- plate. This trend would be expected by the higher hardness values shown

W E L D I N G R E S E A R C H S U P P L E M E N T ! 141-s
in Table 5 for corresponding spec- shape of the junction of the root sur- nearly transverse to the stress d i -
imens. face with the root face. For example, rection than that on the other side of
Weld cracking occurred in tests Y17 at the junction of the root surface with the j o i n t . This w o u l d o r i e n t t h e
and Y18 under the same restraint the side of the joint having the single- hardened heat-affected zone into a
conditions as for tests Y13 and Y14. bevel preparation, Fig. 7 shows a more favorable position for cracking
This is attributed to the higher stress rather gentle notch effect, but Fig. 8 on the one side of the joint. This may
level imposed on the weld due to the shows a sharper effect. In specimens also be a factor in the greater tenden-
smaller weld size in tests Y17 and Y18 having a straight root opening of cy for cracking of the Y-groove spec-
resulting from the lower energy input, about 0.08 in. (2 mm), the sharpest imen having a straight rather than an
relative to tests Y13 and Y14. Hard- notch was at the junction with the side angled root opening (Fig. 10).
ness data indicate that, despite the having the 90 degree preparation. The occasional occurrence of toe
differences in energy input, the weld The weld root surface formed typ- cracks (Fig. 6) is related, most p r o b -
metal microstructures were similar ically an angle of about 60 degrees ably, to a particularly sharp junction
and hence should have a similar (Fig. 10), and sometimes as low as 30 of the surface of the weld and the
cracking tendency. degrees, with this side of the root steel. Such junctions could also con-
With the correct root opening pro- face. tribute to the form of weld cracking
vided by EDM in 1 in. (25 mm) plate, In the angled root openings that shown in Fig. 8 where it is probable
all cracking (Table 4) was in the heat- had widths of about 0.02-0.04 in. (0.5- that cracking traveled upward from
affected zone except in some cases 1 mm), the weld root surface was the root and downward from the toe.
where the upper portion of the crack usually not perpendicular to the thick- Root openings prepared by EDM
deflected into the weld (as in Fig. 7). ness dimension of the specimen and machining in one piece Y-groove
With the angled or oblique root open- an angle of about 30 degrees was specimens were found to be consis-
ing (Fig. 4), cracking was " m e d i u m " in formed by the root surface and the tently within the recommended toler-
severity. With the vertical or straight root face on the side of the joint hav- ence for the opening. However, a pos-
root opening (Fig. 4), cracking sever- ing the single-bevel preparation. This sibly adverse factor relative to using
ity was increased significantly. usually resulted in the presence of a EDM for root opening preparation
Preheating to 200 F (93 C) eliminated particularly sharp notch at the junc- was the observation that the cutting
cracking with both types of root open- tion of the weld and root face. In all process resulted in the presence of
ing orientations. It has been sug- such specimens, when cracking oc- small areas of remelted metal located
gested (Ref. 2) that the reason for the c u r r e d , it was initiated at these intermittently along the cut surfaces
greater severity of the specimen hav- notches and propagated into the weld and when such areas were austen-
ing a straight root opening, as c o m - metal in a direction approximately itized by the test weld, a coarse, only
pared to the specimen having an parallel to the c o l u m n a r g r o w t h slightly tempered martensite resulted.
angled root opening, is the greater pattern. The origin and path of crack- It is expected that such zones would
stress concentration in the vicinity of ing were similar to that shown in Fig. occur at some points along the test
the root of weld and the base metal in 6, although in this case the notch portion just at the intersection of the
t h e f o r m e r s p e c i m e n . T h i s was effect was less severe than in most of root face and the test weld. Because
thought to be related to the dif- the specimens having root openings of the microstructure in these zones,
ference in the angle f o r m e d between of 0.02-0.04 in. (0.5-1 m m ) . It is cracking would be more apt to be ini-
the weld metal and the base metal at thought that with root openings in this t i a t e d t h a n in t h e n o r m a l h e a t -
the weld root; the angle being small- range, weld cracking was usually affected zone, i.e., resulting only from
est in t h e s p e c i m e n h a v i n g t h e favored by the combination of the the test weld thermal cycle.
straight root opening. sharper notch and the orientation of The following conclusions are par-
A comparison of tests Y9 and Y10 the columnar growth pattern of the ticularly valid for the steel plate and
(Table 3) with tests YY9 and YY10 weld metal. The narrower root electrodes as employed in this study
(Table 4) indicates that, in the 1 in. (25 openings appeared to promote a but should be at least partially valid
mm) Y-groove specimens, a root growth pattern (Fig. 6) in the region of for other steels and electrodes.
opening much less than the recom- the notch, adjacent to the side of the
mended value of 0.08 in. (2 mm) tends joint having the single-bevel prep- Conclusions
to produce only weld metal cracking, aration, that was more nearly trans-
1. The CTS fillet weld specimen
w h e r e a s w i t h the r e c o m m e n d e d v e r s e to t h e d i r e c t i o n of s t r e s s
provides less severe conditions for
o p e n i n g only heat-affected zone developed by the weld shrinkage act-
the d e v e l o p m e n t of heat-affected
cracking occurs. ing against the restraint of the spec-
zone cracking than does the Y-groove
imen, than in the case of specimens
The configuration of the weld metal butt weld specimen. Cracking may
(Fig. 7) having a root opening of the
appears to have a significant effect not occur in CTS tests under even
order of 0.08 in. (2 mm).
upon cracking in the Y-groove test. m o r e severe c o n d i t i o n s , s u c h as
Examination of many sections from With root openings of about 0.08 in. lower energy input levels, higher plate
the current study showed that, with an (2 mm), cracking was normally ini- carbon-equivalent values and c o m -
angled root opening of about 0.08 in. tiated at the intersection of the root bined plate thicknesses, which result
(2 mm), the weld root surface was surface and the side of the joint hav- in severe heat-affected zone crack-
usually close to being perpendicular ing the double-bevel preparation, ing in Y-groove tests. Thus, much
to the thickness dimension of the (Figs. 7, 8 and 9). Except for test Y4 caution should be employed in basing
specimen as in Fig. 7, although Fig. 9 (Fig. 8) in 1-1/2 in. (38 mm) plate conclusions concerning cracking t e n -
shows an e x c e p t i o n to this. The under full restraint conditions, crack- dencies at the root pass of butt joints
angles formed by the root surface and ing was always initiated as heat-af- upon the results of fillet weld crack-
the root faces were nominally usually fected zone cracking. Figure 7, which ing studies.
about 60 and 120 degrees respec- is representative of most of the sec- 2. In employing the Y-groove spec-
tively, with the smallest angle being at tions from specimens having a root imen on heavier plate, such as 1 -
the side of the joint having the single- opening of 0.08 in. (2 mm), shows a 1/2 in. (38 mm) thick plate, severe
bevel p r e p a r a t i o n . However, the "wineglass" configuration in which weld metal cracking is likely to occur
sharpness of the notch was variable the lower portion of the fusion line preferentially at high restraint levels,
even with the same nominal angular on the side of the joint having the thus inhibiting the assessment of the
formation, due to variations in the double-bevel preparation is more propensity of the steel to heat-

142-s | M A Y 1976
affected zone cold cracking. At a heat-affected zone cracking occurs thermal cycle of the test weld may be-
much lower level of restraint in 1-1/2 under otherwise similar test condi- come more sensitive to crack ini-
in. (38 mm) thick plate, weld metal tions. tiation than the steel which is being
cracking is eliminated and severe 6. In Y-groove specimens, crack- examined for heat-affected zone
heat-affected zone cracking then oc- ing which initiates from the root of cracking susceptibility. Consequent-
curs. Such cracking is eliminated by weld appears to be influenced signif- ly, it is concluded that the two piece
preheating at a temperature of 300 F icantly by the configuration of the specimen, specially machined to pro-
(149 C). weld metal and this configuration is vide automatic control of the root
3. Weld metal cracking is severe affected by the width of the root open- opening is a more reliable solution to
even with root openings of the order ing. the problem.
of 0.04 in. (1 mm), i.e. much less 7. In 1 in. (25 mm) Y-groove spec-
than the recommended value of 0.08 imens, a significantly greater extent of References
in. (2 mm), when the 1-1/2 in. (38 mm) heat-affected zone cracking tends to
Y-groove specimen is unslotted and occur when the root opening orienta- 1. Hensler, J. H., Graham, J . W., and
thus provides high restraint. tion is straight rather than angled as is Cullen, G. V., "Cold Cracking Tests for
Determination of Weldability-Assessment
4. Moderate to severe heat-affect- normally employed. All cracking is
of the Tekken Test," Australian Welding
ed zone cracking, initiating at weld eliminated by preheating to 200 F Research, 1 (9), p 1, 1970.
toes which cause a particularly severe (93 C). The greater severity of spec- 2. Sasaki, H., Watanabe, K.. Kirihara,
notch effect, is likely to occur in Y- imens having the straight root open- S., and Sejima, I., "Effects of Restraint
groove specimens in 1-1/2 in. (38 mm) ing may be due, in part, to orientation Stress and Intensity of Restraint on De-
plate under conditions of high re- of the heat-affected zone to a more l a y e d C r a c k s in t h e W e l d s of 80
straint. favorable position for crack develop- k g / m m 2 / H i g h - S t r e n g t h Thick-Plate Steel"
5. In 1 in. (25 mm) Y-groove spec- ment, relative to the stress direction, — IIW Document IX-784-72 (X-654-72),
than in specimens having the angled July 1972.
imens, weld metal cracking rather
root opening. 3. Goda S., Sato, M., Nakai, T.. Ando,
than heat-affected zone cracking oc- A., and Minehisa, S., "Weld Bond Frac-
curs when the root opening is much 8. Although the EDM process per- ture and a New 80 k g / m m 2 High-Strength
less than the recommended value of mits good control of the root opening, Steel for Submerged Arc Welding" — IIW
0.08 in. (2 mm). When the latter value it produces small zones along the cut Document IX-632-69 (X-527-69), July
is provided by the EDM process, only edge which, when subjected to the 1969.

WRC Bulletin
No. 184
June 1973

"Submerged Arc Weld Hardness and


Cracking in W e t Sulfide Service"

by D. J. Kotecki and D. G. Howden

This study was undertaken to determine:


(1) The causes of higher-than-normal hardness in submerged-arc welds in plain-
carbon steels
(2) The levels of strength or hardness which will not be susceptible to sulfide-
corrosion cracking
(3) Welding procedures which will assure that nonsusceptible welds will be
produced.
Concentration is primarily on weld metal, though some consideration to the
weld heat-affected zone is given. The study covered a two-year period. The first
year was concerned with a macroscopic view of the weldments. In that first-year
study, some inhomogeneities were observed in weldments which are not obvious
in a macroscopic view of the weldment. It appeared likely that these
inhomogeneities could affect the behavior of the weldment in aqueous hydrogen-
sulfide service. Accordingly, their presence and effects were investigated during
the second year.
The price of WRC Bulletin 184 is $3.50 per copy. Orders should be sent to the
Welding Research Council, 345 East 47th Street, New York, N.Y. 10017.

W E L D I N G R E S E A R C H SU P P L E M E N T I 143-s
1975 STRUCTURAL WELDING CODE

The new edition of the Structural Welding Code, AWS


Dl.1-75 is here — completely revised with important require-
ments that you need to know.

Automatic Revision Service


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the 1976 and 1977 Revisions, automatically sent to you as
they are published.

Sturdy 3-Ring Binder


The heavy-duty vinyl binder will hold the Structural
Welding Code, the soon-to-be published Code Commentary,
and the Reinforcing Steel Welding Code, AWS D12.1-75 (the
latter two documents to be sold separately). The binder in-
cludes dividers for the main sections of Dl.1-75 as well as the
other two publications mentioned.
A limited number of soft cover bound copies is available.

Structural Welding Code


1. Looseleaf text, Dl.1-75, in binder with dividers plus
1976 and 1977 revisions $25.00
2. Soft cover bound text, Dl.1-75, plus 1976 and 1977 revisions $24.00
Reinforcing Steel Welding Code, AWS D12.1.75 soft-cover, bound $5.00
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Discounts: 25 percent to A and B members; 20 percent to bookstores,
public libraries and schools; 15 percent to C and D members. Add 4 per-
cent sales tax in Florida. Send orders to: American Welding Society, 2501
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144-s I MAY 1976

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