WELDING

METALLURGY
1

ADVANCED
MANUFACTURING COURSE

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 OVERVIEW
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 Introduction
 The Generation of Heat in Welding
 Temperature Changes in Welding
 Changes in the Microstructure

References
 G. E. Linnert, Welding Metallurgy: Carbon and Alloy Steels, 3rd
ed., AWS, 1965.
 ESDEP no.20 – Film on Welding Steel Structure

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Welding Class
 APLIKASI
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 Rivet: frame pintu/jendela; jembatan, pesawat

terbang lama
 Forged welding: Damascus sword
 Thermit welding: railways, Cu conductor
 Ultrasonic welding:
 Electron beam welding: Ti turbine blade repair weld,
compressor, rotor,orthopaedic
 SAW: LPG pressure tank
 Electroslag welding: bodi kapal, struktur tank
 Plasma arc welding: turbine blade, pipa SS/Ti,
aerospace 12/2/2019
 APLIKASI
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 Pressure cold welding: joining of wire

 Percussion welding: electronic circuit
 Friction welding: tube, shaft, rotor aeroengine
 Flash butt welding: railways
 SMAW:rangka mobil (?)

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To deposit a uniform, well penetrated weld:
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 Skilled welders
 Understand the materials to be welded

The welding operation heats metals, and that heat inevitably

changes not only the metal’s initial heat treated structure
but its properties as well. But a skilled welder can
minimise damage to sensitive microstructures and their
properties. Even a minimal knowledge of metallurgy is
helpful.

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 IMPORTANT ISSUES
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Our best means of dealing with these undesirable side effects

from heating is
 To know the temperature reached by every part of the weld joint
area, and
 The subsequent cooling history
 Then by
controlling
these
temperatures
and cooling cycles
we can act to
minimise the
more troublesome
effects of heating.
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Unmixed Zone
 Narrow region adjacent to the
fusion boundary
 Completely melted and
resolidified base metal
 No mixing with the bulk fusion
zone (composite region)
Partially Melted Zone
 Region separating the fusion
zone from the “true”
heataffected
 zone
 Transition from 100% liquid at
the fusion boundary to 100%
 solid in the HAZ
 Localized melting normally
observed at grain boundaries
 Constitutional liquation of
certain particles
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 The Generation of Heat
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Three basic sources employed for gaining the thermal

energy ultimately used in our present welding
operations:
1. Electrical: electric arc, electron beam, electrical
resistance, and electromagnetic radiation.
2. Chemical: thermit process.
3. Mechanical: friction welding.

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 Heat and Time in Welding
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Electric Arc
W (joules) = E (volts) x I (ampere) x t (seconds)
Electron Beam-2
Q (cal/min) = 6.98x10 x E (volts) x I (ampere)

Electric Resistance
W (joules) = I (amperes) x R (ohms) x t (seconds)
2

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 What are the
Thermal Effects consequencies of
heating and cooling
Caused by Arc during welding?
Welding

Conduction
Figure 5. Diagram of the heat-affected zone: (I)
and radiation
overheated section, (II) grain-refined (normalized)
section, (III) partially grain-refined section, (IV) cool the metal
recrystallized section, (V) aging section; (1) weld metal,
(2) fusion zone

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 Important Factors Affects the Base Metal
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 Rate of heating: depend upon the intensity of the

heat source and the efficiency of heat transfer.
 Maximum temperature: determined by the rate of
heat input and the rate of heat loss.
 Length of time at temperature
 Rate of cooling
 Cooling end-point

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 Temperature Distribution

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 Time At Temperature

 Depends upon the

maintaining of an even
balance between heat input
and heat loss.
 The heat input > the heat
loss → maximum
temperature has not been
reached.
 The heat input < the heat
loss → cooling from the
maximum temperature .
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 TEMPER COLOURS

To determine the maximum temperature reached by the heat-

affected base metal at varying distances on each side of the
weld joint after the joint has cooled.

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 COOLING RATE

Three general features have a

profound influence upon the
cooling rates:
1. The weld nugget which acts as
a heat source.
2. The mass of base metal which
represents a heat sink.
3. The temperature of the base
metal, which establishes the
initial temperature gradient.

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 Heat Affected Zone (HAZ)
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Fig.4. Spot weld in 2mm DP800

showing variation in notch profile
at the edge of the nugget
(Ref:http://www.twi-global.com/technical-
knowledge/published-papers/the-resistance-spot-
welding-of-high-and-ultra-high-strength-steels-
november-2004/)

Figure 1. Macro sections of GMAW weld

W01 (left) and SMAW weld W02 (right)
(ref:http://www.twi-global.com/technical-
knowledge/published-papers/effect-of-inclusions-on-
the-fracture-toughness-girth-welded-line-pipe/) 12/2/2019
 Size of HAZ

The size of HAZ depends on:

1. The relative size of the weld metal and the plate.
2. The amount of preheat in the plate – the higher the
preheat, the larger the HAZ

!! The metallurgical changes occuring within the HAZ

depend on the alloy and its initial microstructure.
!! The HAZ need not always be small. A larger HAZ is
desirable for welding the steels that can produce
martensite at the same cooling rates as those
produced when welding heavy plate.
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Look At Two Types of Alloy Systems
Cold Worked Alloy Without Allotropic Transformation

Introductory Welding Metallurgy,

AWS, 1979
Welding
Precipitation
Hardened Alloys
Without Allotropic
Phase Changes

Welded In:
• Full Hard
Condition
• Solution
Annealed
Condition
Annealed upon
Cooling
Precipitation Hardened Alloy Welded in Full Hard Condition

Introductory Welding Metallurgy

AWS, 1979
Precipitation Hardened Alloys Welded in Solutioned Condition

Introductory Welding Metallurgy,

AWS, 1979
Steel Alloys With Allotropic Transformation

Introductory Welding Metallurgy,

AWS, 1979