Development of the Naval

Welding Engineers’ Toolkit

(NAVWET)
National Shipbuilding Research Program
Welding Technology Panel Meeting
March 9, 2017

Daniel Bechetti
Welding, Processing, and NDE Branch
Naval Surface Warfare Center, Carderock Division

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

 Overview

• Background Examples of currently available software:

– Naval engineers routinely perform a variety of welding-related

calculations to develop welding procedures and testing plans
– Software to perform some of these calculations exists but requires
paid licenses and computer compatibility
– Many of these calculations are made using spreadsheets designed
and maintained by individual engineers NavWeld (Weld QC)

• Objectives
– To develop a suite of calculators for naval welding-related
problems, standardize routine calculations, and acquire reasonable
estimates for more complex calculations
– To build/provide this suite in a ubiquitous software platform so
that it can be easily distributed and updated
– To provide technical references wherever possible so that
calculation methods are clear and can be explored further if desired
SmartWeld (Sandia National Labs)

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 2

 NAVWET
• Naval Welding Engineers’ Toolkit
developed and maintained by NSWC
Carderock
– Computational reference tool
– Built in and run from MS Excel
– Current version contains three ‘modules’ that
perform groups of related calculations
– Technical references provided wherever possible
and detailed descriptions of the calculation
methods and assumptions provided
– All relevant data stored within the spreadsheet

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 3

 Module 1: Preheat Determination
Purpose:
• To provide reference compositions of typical Naval steels
• To provide a standard calculator for carbon equivalent
• To provide base metal and filler metal preheat and interpass
requirements for S-1, S-2, and S-11 materials as outlined in Tech.
Pub. 1688, Rev. 1

Inputs:
• Base materials

Method:
• Cross-references user inputs with composition database

Outputs:
• Reference nominal compositions for 175 base material and filler
materials variants

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 4

 Module 1: Preheat Determination
Purpose:
• To provide reference compositions of typical Naval steels
• To provide a standard calculator for carbon equivalent
• To provide base metal and filler metal preheat and interpass
requirements for S-1, S-2, and S-11 materials as outlined in Tech.
Pub. 1688, Rev. 1

Inputs:
• Base materials
• Filler material

Method:
• Cross-references user inputs with composition database

Outputs:
• Reference nominal compositions for 175 base material and filler
materials variants

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 5

 Module 1: Preheat Determination
Purpose:
• To provide reference compositions of typical Naval steels
• To provide a standard calculator for carbon equivalent
• To provide base metal and filler metal preheat and interpass
requirements for S-1, S-2, and S-11 materials as outlined in Tech.
Pub. 1688, Rev. 1

Inputs:
• Base materials
• Filler material
• Carbon equivalent method

Method:
• Cross-references user inputs with composition database

Outputs:
• Reference nominal compositions for 175 base material and filler
materials variants
• Carbon equivalent values from the user’s choice of 8 calculation
methods

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 6

 Module 1: Preheat Determination
Purpose:
• To provide reference compositions of typical Naval steels
• To provide a standard calculator for carbon equivalent
• To provide base metal and filler metal preheat and interpass
requirements for S-1, S-2, and S-11 materials as outlined in Tech.
Pub. 1688, Rev. 1

Inputs:
• Base materials
• Filler material
• Carbon equivalent method
• Thickness
• Welding Process

Method:
• Cross-references user inputs with composition database and
preheat tables, including footnotes

Outputs:
• Reference nominal compositions for 175 base material and filler
materials variants
• Carbon equivalent values from the user’s choice of 8 calculation
methods
• Itemized preheat and interpass requirements for the selected base
and filler metals
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 7
 Module 2: Thermal Behavior
Purpose:
• To provide reasonable estimates of fusion zone cooling rate,
weld pool size, heat affected zone (HAZ) size, HAZ thermal
cycle, and coarse grained HAZ cooling time

Inputs:
• Welding parameters or heat input

Method:
• Fusion zone cooling rate – calculation process described in
AWS Welding Handbook and ASM Materials Handbook

Example Outputs:
1. Cooling rate of weld metal at the chosen temperature, with
tabulation for comparisons

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 8

 Module 2: Thermal Behavior (Cont.)
Purpose:
• To provide reasonable estimates of fusion zone cooling rate,
weld pool size, heat affected zone (HAZ) size, HAZ thermal
cycle, and coarse grained HAZ cooling time

Inputs:
• Welding parameters or heat input

Method:
• Fusion zone cooling rate – calculation process described in
AWS Welding Handbook and ASM Materials Handbook
• Time-temperature data – Rosenthal model for 2-D and 3-D
heat flow

Example Outputs:
1. Cooling rate of weld metal at the chosen temperature, with
tabulation for comparisons
2. Automatic plotting of steady-state isotherms at chosen
FZ
temperatures FGHAZ
HAZ Edge

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 9

 Module 2: Thermal Behavior (Cont.)
Purpose:
• To provide reasonable estimates of fusion zone cooling rate,
weld pool size, heat affected zone (HAZ) size, HAZ thermal
cycle, and coarse grained HAZ cooling time

Inputs:
• Welding parameters or heat input

Method:
• Fusion zone cooling rate – calculation process described in
AWS Welding Handbook and ASM Materials Handbook
• Time-temperature data – Rosenthal model for 2-D and 3-D
heat flow

Example Outputs:
1. Cooling rate of weld metal at the chosen temperature, with
tabulation for comparisons
2. Automatic plotting of steady-state isotherms at chosen
temperatures
3. HAZ thermal cycle for chosen distance from weld
centerline, with optional overlay on CCT diagram

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 10

 Module 2: Thermal Behavior (Cont.)
Purpose:
• To provide reasonable estimates of fusion zone cooling rate,
weld pool size, heat affected zone (HAZ) size, HAZ thermal
cycle, and coarse grained HAZ cooling time

Inputs:
• Welding parameters or heat input

Method:
• Fusion zone cooling rate – calculation process described in
AWS Welding Handbook and ASM Materials Handbook
• Time-temperature data – Rosenthal model for 2-D and 3-D
heat flow

Example Outputs:
1. Cooling rate of weld metal at the chosen temperature, with
tabulation for comparisons
2. Automatic plotting of steady-state isotherms at chosen
temperatures
3. HAZ thermal cycle for chosen distance from weld
centerline, with optional overlay on CCT diagram

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 11

 Module 2: Thermal Behavior (Cont.)
Purpose:
• To provide reasonable estimates of fusion zone cooling rate,
weld pool size, heat affected zone (HAZ) size, HAZ thermal
cycle, and coarse grained HAZ cooling time

Inputs:
• Welding parameters or heat input

Method:
• Fusion zone cooling rate – calculation process described in
AWS Welding Handbook and ASM Materials Handbook
• Time-temperature data – Rosenthal model for 2-D and 3-D
heat flow

Example Outputs:
1. Cooling rate of weld metal at the chosen temperature, with
tabulation for comparisons
2. Automatic plotting of steady-state isotherms at chosen
temperatures
3. HAZ thermal cycle for chosen distance from weld
centerline, with optional overlay on CCT diagram
4. Cooling time from 800°C to 500°C

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 12

 Module 3: Dilution in Overlays

Purpose:
• To calculate the amount of dilution (base metal mixing) in
a weld overlay or cladding
• To calculate the composition of an arbitrary layer in the
overlay or cladding

Inputs:
• Substrate and overlay material class
• Welding parameters

Method:
• Thermodynamic data calculated using ThermoCalc
• Dilution percentage determined using the method
described by DuPont and Marder

Outputs:
• Dilution percentage

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 13

 Module 3: Dilution in Overlays

Purpose:
• To calculate the amount of dilution (base metal mixing) in
a weld overlay or cladding
• To calculate the composition of an arbitrary layer in the
overlay or cladding

Inputs:
• Substrate and overlay material class
• Welding parameters

Method:
• Thermodynamic data calculated using ThermoCalc
• Dilution percentage determined using the method
described by DuPont and Marder
• Composition calculations performed using bead-on-plate
welding equations, assumptions made for layers other
than the first

Outputs:
• Dilution percentage
• Deposited weld metal composition for a chosen layer

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 14

 Future Plans

• Fillet weld sizing and design

- To organize and simplify the many possible weld computation factors described in MIL-STD-1628A

• Weld metal constitution diagrams

- For prediction of weld metal solidification mode in similar and dissimilar welds

• Experimental validation of some current calculations to validate assumptions

• Distribution to warfare centers and public shipyards in CY17 for initial testing, user feedback, and
refinement

Fillet weld computational factors from MIL-STD-1628A

WRC-1992 constitution diagram

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. 15

 Questions?

Acknowledgements
This work was funded by NSWC Carderock Division under the Naval Innovative
Science and Engineering (NISE) NDAA Section 219 program, managed by the NSWC
Carderock Division Director of Research

The software presented herein is intended as a reference, estimation, and comparison

tool. It is incumbent upon individual users to verify conformance of outputs to NAVSEA
directives. No liability is assumed by NAVSEA, NSWCCD, or their employees regarding
the use, output, or application of this software.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.