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DOI 10.1007/s12666-016-0927-3
TECHNICAL PAPER
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this steel has been estimated using International Institute of using CDV100 filler wire and also with filler wire of
Welding (IIW) CE evaluation formula [3, 4], which is composition same as that of the base metal.
around 0.951 %. IIW recommends preheating and post- Hot rolled and annealed plates of 7.8 mm thickness
weld heat treatment to avoid cracking in the heat affected were used to realize weld coupons. The chemical com-
zone (HAZ) for carbon equivalents above 0.40 % [5] and position of the base metal coupon (steel) used in this
therefore present steel warrants a pre heating operation. study is given in Table 1. Straight butt weld (square
Considering the above, the present work highlights the groove, Fig. 1a) with 0.05–0.1 mm root gap was used for
studies carried out to establish single pass plasma arc welding the coupons of dimensions 500 mm 9 300
welding technology for 0.3 % C–CrMoV (ESR) steel. mm 9 7.8 mm. The chemical composition of the
Extensive characterization has been carried out and weld CDV100 filler wire is given in Table 2. The welding
efficiency of the weldment has been calculated. Attempts parameters are given in Table 3. Trials were carried out
have been made to correlate microstructure with the using Cu back-up bar with pre heat of 200 °C, without
achieved mechanical properties. preheat, water cooled Cu back-up bar and stainless steel
back-up plate (without preheat).
Three numbers of 500 mm 9 300 mm 9 7.8 mm thick
2 Experimental Trials plates bearing identifications HN-1, HN-2 and HN-3 were
welded using the weld parameters given in Table 3 with
Welding studies were carried out to analyze the effect of weld configuration as presented in Table 4. Photograph of
preheat and use of back up material (stainless steel and weld edge details and welded coupon with testing
copper). Single pass plasma arc welding was carried out scheme are presented in Fig. 1.
0.29 0.97 1.44 0.27 0.93 0.10 0.13 0.004 0.009 Bal
Fig. 1 a Weld edge drawing showing cross section, b welded coupon and c scheme of tensile test and compact tensile test (CT) specimen for
fracture toughness evaluation
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Table 2 Chemical composition of CDV100 filler wire evaluation of the tensile, fracture toughness properties after
C Mn Mo Cr V Si S P Fe
sand blasting. Tensile test was carried out as per ASTM E8
and fracture toughness was carried out as per ASTM E399
0.15 1.00 0.82 1.4 0.26 0.2 0.02 0.018 Bal on specimens of configuration shown in Fig. 2a, b.
Microhardness measurement of the weldments was
conducted on specimens in as-welded as well as in heat
Argon gas was used for plasma, shielding, backing and treated condition. Mechanical property evaluation of the
trailing. The bead width was measured after welding. The base metal and weldment was carried out in the as hard-
reinforcement was ground to match plate thickness. All the ened and tempered condition. The heat treatment cycle
coupons were subjected to dye penetrant testing and adopted is:
radiographic testing. Hardening 920 ± 10 °C—soak for 1 h-oil quenching to
The weldment was subjected to hardening and temper- room temperature (Quench delay \45 s)
ing after applying anticarb coating to minimize decarbur- followed by
ization. Sand blasting was done to remove scales and oxide Tempering 450 ± 10 °C—soak for 2 h-oil quenching to
layers. Specimens were prepared from the weldment for room temperature (Quench delay \45 s)
Fig. 2 a Tensile test and b fracture toughness test specimen (dimensions are in mm)
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Metallographic evaluation was carried out in both as Table 6 Mechanical properties of weldment using CDV100 filler
welded condition and after PWHT (hardened and tem- after PWHT (hardened and tempered condition)
pered) condition. The samples were polished using con- 0.2 % P.S (MPa) UTS (MPa) %El (G.L = 50 mm)
ventional metallographic polishing technique and etched
using 2 % Nital. 1299–1327 1398–1442 12.2–13.0
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400 400
VHN
VHN
350 350
300 300
250 250
200 200
-16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 -16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20
Distance in mm from weld centre Distance in mm from weld centre
(c) 600
With Cu backing bar (d)
550 Top (Crown)
Middle 550
Root With Water cooled
500
500 Cu backing bar
Top (Crown)
450 450 Middle
Root
400 400
VHN
VHN
350 350
300 300
250 250
200 200
-16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 -18 -16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18
Distance in mm from weld centre
Distance in mm from weld centre
Fig. 4 Microhardness plots with different backing bar material in the as welded condition a with stainless steel backing bar, b with Cu backing
bar ? preheating, c with Cu backing bar, d with water cooled Cu backing bar material
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In the process of welding, three zones were created, significant changes in properties are observed due to
weld metal, heat affected zone (HAZ) and base metal. With change in filler wire.
faster cooling of weld metal, austenite transformed by 3. Microhardness of weldment after post weld heat
diffusionless transformation to form martensite. HAZ area treatment is found to be in the range of 480–520
which had experienced high temperature and transformed VHN, which is similar to heat treated base metal
to austenite during welding, further transformed to lath indicating air hardenability of weldment.
martensite. Further, during hardening and tempering, 4. Effect of backing bar material on mechanical proper-
weldment consisted of tempered martensite and martensite ties are found to be insignificant. However, process
laths coarsened in the HAZ. Finally, HAZ became weaker difficulty is noted in using stainless steel backing bar
zone. with respect to breaking of weld tacks and occasional
Metallographic evaluation showed HAZ of width burn through of coupon.
*2.5 mm in the as welded condition. Optical microstruc-
ture of the weldment with different filler wire as well as Acknowledgments We express our sincere thanks to DD, MME,
different back-up bar material did not show significant VSSC for his constant encouragement and support. We are extremely
variation. The representative photomicrographs of various thankful to the management and staff of M/s L&T, Powai for their
zones are given Fig. 5. Optical microstructure of post weld valuable suggestions and help rendered during the course of the above
studies. Thanks are also due to all our colleagues in VSSC for their
heat treated (PWHT) weldment did not reveal any specific support in heat treatment, machining, testing and characterization of
feature where martensite was transformed to tempered the specimens.
martensitic.
References
4 Conclusions
1. Chatterjee M, Balasubramanian, M S N, Gupta K M, and Rao P K,
J Ironmak Steelmak 17 (1990) 38.
1. Plasma Arc Welding Technology and parameters have 2. Irving B, Weld J 74 (1995) 43.
been evolved for single pass straight butt welding of 3. Linnert G E, Welding Metallurgy, Vol. 2. 3rd Ed. American
7.8 mm thick plates of 0.3 % C–CrMoV (ESR) steel. Welding Society, Miami (1967).
4. Seferian D, The Metallurgy of Welding, Wiley, New York (1962).
2. Mechanical property evaluation for PAW with
5. Coe F R, Welding Steels Without Hydrogen Cracking, The
CDV100 filler wire as well as with filler wire of base Welding Institute, Cambridge (1973).
metal composition has yielded [85 % efficiency for
both tensile and fracture toughness values. No
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