Experiment 3

Microstructural Analysis and Hardness Profiling of Welded Parts

I. Learning Objectives
1. Understand the concepts and principles behind welding.
2. Relate the microstructure of the welded part to the operating parameters during welding.
3. Relate the hardness profile with the different zones of the weld.

II. Pre-laboratory Questions

1. What is electric arc welding?
2. What are the recommended settings when welding plain carbon steels? Stainless steels?
3. What are the different types of welding joints? Differentiate each type by providing an
illustration or schematic.
4. What are the three distinct regions of the weldment?
5. Why is preheating done for some alloys?
6. What are the standard PPE needed during welding?
7. What hazards must be considered during welding? What preventive or safety measures
must be remembered during welding?
8. Prepare a table of etchants (composition and procedure) for both microetching and
macroetching of common steel specimens.

III. Materials And Equipment

Steel samples SiC papers
Steel cutting tools Alumina (0.1μ and 0.05μ)
Electric arc welding equipment Polishing wheel
Etchant Microscope

IV. Procedure
A. Preparation
1. Observe the laboratory technicians as they demonstrate the procedure for making a
good weld on steel bars.
2. Weld the steel bar pairs together on its long side.
3. Practice until a satisfactory weld is produced.

B. Experiment Proper
1. Weld three pairs of 4” long x 1.5” steel bars.
2. Immediately after welding each pair, do the following:
Welded Bars Treatment
1 Air-cool
2 Water-quench
Water-quench then tempered
3
at 500°C for 20 mins
C. Metallographic Analysis
1. Prepare a transverse and longitudinal sectional section of each weld. Ensure proper
lubrication to prevent unwanted metallographic changes in your sample. Also, show a
schematic diagram in your pre-lab notebook on how the specimen will be sectioned.
 2. Prepare the sections for metallographic analysis.
3. For macroethcing of both sections,
Option 1:
a. Dissolve 10 g of (NH4)2S2O8 (ammonium persulfate) in 100 mL H2O.
b. Swab solution at room temperature over specimen.
c. Rinse and dry.
Option 2:
a. Prepare 1:1 HCl to H2O solution.
b. Heat the solution at 75°C and immerse the specimens.
c. Desmut by vigorously brushing with vegetable fiber brush under running
water.
4. For microetching, repolish (regrind if necessary) the macroetched specimen.
5. Microetch using nital, along the transverse surface and take photomicrographs.
6. Repolish transverse surface then take microhardness readings.

V. Discussion Guide
1. Describe a good weld. Show pictures of the best butt weld produced by the group.
Show pictures of the worst butt weld and discuss which features or characteristics
make it unacceptable.
2. Discuss the technique necessary to produce a good butt weld.
3. What operating parameters/ settings can be controlled or changed during welding?
How do these affect the weld?
4. Relate the hardness profile along the transverse axis with the macroetched surface.
Discuss significant values and changes.

VI. Keywords
Welding, welding joint, fusion zone, heat-affected zone, base metal, microstructure,
hardness, annealing