Cracking

Cracks occurs in three locations

Weld metal
Fusion line
Base metal HAZ
Crack classification in groove weld
1. Hot crak & cold or delay crack
2. Weld metal crater cracking
3. Weld metal transverse cracking
4. Base metal HAZ transverse cracking
5. Weld metal longitudinal cracking
6. Toe cracking
7. Under bead cracking
8. Fusion line cracking
9. Weld metal root cracking

Crack classification in groove & fillet weld

1. Crater crack
2. Face crack
3. Heat affected zone crack
4. Lamellar tear
5. Longitudinal crack
6. Root crack
7. Root surface crack
8. Throat crack
9. Toe crack
10. Transverse crack
11. Under bead crack
12. Weld inter face crack
13. Weld metal crack

Characteristics and occurrence of hot cracking

Occure at 1000f and above

Where the crack has extended to the surface and air allowed to enter the fractured surfaces found coated
with oxide

Hot cracking in solidifying welds

Hot cracks always appear to initiate at allocation behind the solidification
Hot cracks in weld beads may occur because the cooling of the joint results in contraction of the weld
metal and base metal which imposes stresses upon the weld metal.
Hot crack in a restrained fillet weld bead on left of vertical member was deposited after the one on the right
Hot crack developed in the left bead because of greater degree of restraint

Defects hydrogen cracking in steels (ref. TWI )

Hydrogen cracking may also be called cold cracking or delay cracking occur in ferritic steels
Immediately on or after a short time after welding
Hydrogen cracks originating in the heat affected zone the type of cracks shown would not be expected to
form in the same weld metal

On breaking open the weld (prior to any heat treatment the

surface of the cracks will normaly not be oxidized even if
they are surface breaking
A slight blue tings may be seen from the effects of
preheating or welding heat

METALLOGRAPHY
In filler weld cracks in the HAZ are usually associated
with the weld root & parallel to the weld in butt welds
The HAZ cracks are normally parallel to the weld beads.
Fig. 2 Crack along the coarse grain structure in
the HAZ

Causes
There are three factors which combine to cause cracking:
hydrogen generated by the welding process
a hard brittle structure which is susceptible to cracking
residual tensile stresses acting on the welded joint

Cracking is caused by the diffusion of hydrogen to the highly stressed, hardened part of the weldment.

In C-Mn steels, because there is a greater risk of forming a brittle microstructure in the HAZ, most of the
hydrogen cracks are to be found in the parent metal. With the correct choice of electrodes, the weld metal
will have a lower carbon content than the parent metal and, hence, a lower carbon equivalent (CE).
However, transverse weld metal cracks can occur especially when welding thick section components.

In low alloy steels, as the weld metal structure is more susceptible than the HAZ, cracking may be found in
the weld bead.

The effects of specific factors on the risk of cracking are::

weld metal hydrogen

parent material composition
parent material thickness
stresses acting on the weld
heat input

Weld metal hydrogen content

The principal source of hydrogen is the moisture contained in the flux ie the coating of MMA electrodes,
the flux in cored wires and the flux used in submerged arc welding. The amount of hydrogen generated is
determined mainly by the electrode type. Basic electrodes normally generate less hydrogen than rutile and
cellulosic electrodes.

It is important to note that there can be other significant sources of hydrogen eg moisture from the
atmosphere or from the material where processing or service history has left the steel with a significant
level of hydrogen. Hydrogen may also be derived from the surface of the material or the consumable.

Sources of hydrogen will include:

oil, grease and dirt

rust
 paint and coatings
cleaning fluids

Parent metal composition

This will have a major influence on hardenability and, with high cooling rates, the risk of forming a hard
brittle structure in the HAZ. The hardenability of a material is usually expressed in terms of its carbon
content or, when other elements are taken into account, its carbon equivalent (CE) value.

The higher the CE value, the greater the risk of hydrogen cracking. Generally, steels
with a CE value of <0.4 are not susceptible to HAZ hydrogen cracking as long as low hydrogen welding
consumables or processes are used.

Parent material thickness

Material thickness will influence the cooling rate and therefore the hardness level, microstructure produced
in the HAZ and the level of hydrogen retained in the weld.

The 'combined thickness' of the joint, ie the sum of the thicknesses of material meeting at the joint line, will
determine, together with the joint geometry, the cooling rate of the HAZ and its hardness. Consequently, as
shown in Fig. 3, a fillet weld will have a greater risk than a butt weld in the same material thickness.

Fig.3 Combined thickness measurements for butt and fillet joints

Stresses acting on the weld

The stresses generated across the welded joint as it contracts will be greatly influenced by external
restraint, material thickness, joint geometry and fit-up. Areas of stress concentration are more likely to
initiate a crack at the toe and root of the weld.

Poor fit-up in fillet welds markedly increases the risk of cracking. The degree of restraint acting on a joint
will generally increase as welding progresses due to the increase in stiffness of the fabrication.
Heat input

The heat input to the material from the welding process, together with the material thickness and preheat
temperature, will determine the thermal cycle and the resulting microstructure and hardness of both the
HAZ and weld metal.

A high heat input will reduce the hardness level.

Heat input per unit length is calculated by multiplying the arc energy by an arc efficiency factor according
to the following formula:

V = arc voltage (V)

A = welding current (A)
S = welding speed (mm/min)
k = thermal efficiency factor

In calculating heat input, the arc efficiency must be taken into consideration. The arc efficiency factors
given in BS EN 1011-1: 1998 for the principal arc welding processes, are:

Submerged arc 1.0

(single wire)
MMA 0.8
MIG/MAG and flux cored wire 0.8
TIG and plasma 0.6

In MMA welding, heat input is normally controlled by means of the run-out length from each electrode
which is proportional to the heat input. As the run-out length is the length of weld deposited from one
electrode, it will depend upon the welding technique eg weave width /dwell.
Hydrogen cracks in steel prevention

Preheating to avoid hydrogen cracking

Hydrogen cracking may also be called cold cracking or delayed cracking. The principal distinguishing
feature of this type of crack is that it occurs in ferritic steels, most often immediately on welding or after a
short time after welding.

Preheating ,interpass &post heating , drying electrode , cleaning the joint from
oil , paint , . To prevent hydrogen cracking.