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Experimental Investigation of Residual stress and Microstructure in

Shielded Metal Arc Welding (SMAW) of dissimilar metals IS 2062 steel


and SS304 steel
Harshit Desai¹, Bhargav c Patel², Viral Shah3, Harsh Desai4
1, 2,
Assistant Professor, Department of Mechanical Engineering, C G Patel Institute of
Technology
Maliba Campus, Uka Tarsadia University, Bardoli - 394 350, Surat, Gujarat, India.
3, 4,
Students, C G Patel Institute of Technology Maliba Campus, Uka Tarsadia University.
1
harshit.desail@utu.ac.in, 2bhargav.patel@utu.ac.in

ABSTRACT
Purpose: Weld residual stress and thermal stress is to be analyzed for dissimilar metal SMAW
welding of stainless steel to carbon steel. This paper is to investigate the effect of heat input due
to change in the welding speed and its influence on residual stress distribution in weldments.
ASME section 9 and AWS handbook provides generalized guideline for welding and testing
requirements of dissimilar metal like Carbon steel to Stainless steel, welding with above
information may not be practical or not sufficient in highly critical job. Sometimes, compliance
with codes and standard is not sufficient and patterns of residual stress and microstructure
analysis are recommended as and when demanded in critical jobs.

Design/methodology/approach: The use of XRD technique for residual stress measurements


is described. All Sample was prepared on wire cut EDM machine, and which have a thickness
of 4mm and 10mm x 10mm in width and length of the material. In addition, studies of
macrostructure and radiography were conducted.

Findings: Residual stresses in restrained welds and weld repairs are very complex. The heat
input affects the value and distribution of residual stress in the specimen. This peak stress in all
samples occurred not at the toe, but in the middle of the weld bead, where the yield stress is
higher. From the results, we discussed that increase in heat input will increase the residual
stress.

Research implications: Measurements of residual stress can be very expensive and time
consuming. The XRD machine is capable of non-destructive investigation of residual stresses in
specimen. Weld area can be recorded where high heat inputs are applied and prediction of
stress value and metal structure change can be predicted using experimental data of the
research paper. The results may be used to calibrate finite element modelling of the welding
process.

Practical implications: Prediction of residual stress and metal structure will add significant
value in predicting equipment’s behavior in service condition. The findings have important
consequences with respect to design of welding procedures and fitness-for-purpose
assessments.

Originality/value: The authors have used X-Ray Diffraction followed by radiography and
metallography assessment of residual stresses to follow in detail the changes due to heat input
in welded specimen. This paper could be an interesting source of information for engineers and
researchers who work with welded structures of dissimilar metal.

Keywords: SMAW Welding; Residual stresses; XRD; Heat input, Welding Radiography
1. INTRODUCTION resulting in a complex micro structure. The
subsequent heating and cooling results in
Welding is extensively used in fabrication as
setting up internal stresses and plastic strain in
an alternative method for casting or forging and
the weld.
as a replacement for bolted and riveted joints. It
Depending upon the slope of
is also used as a repair medium e.g. to reunite a
temperature gradient three distinct zones as
metal at a crack or to build up a small part that
shown in Figure 2 can be identified in welded
has broken off such as a gear tooth or to repair
joint which are:
a worn surface such as a bearing surface.
1. Base metal
2. Heat Affected Zone (HAZ)
3. Weld metal

Figure 1. Shielded Metal Arc Welding [1]


In SMAW process, the heat is generated Figure 2. Weld Zone [8]
by an electric arc between base metal and a A joint made with a filler metal is called
consumable electrode. In this process electrode weld metal. Since central portion of the weld
movement is manually controlled hence it is bead will be cooled slowly, long columnar grains
termed as manual metal arc welding. SMAW will developed and in the out ward direction
process is extensively used for depositing weld grains will become finer and finer with distance.
metal because it is easy to deposit the molten So the ductility and toughness decreases away
weld metal at right place where it is required and from the weld bead. However strength increases
it doesn’t need separate shielding. This process with the distance from the weld bead. The
is commonly used for welding of the metals, original structure in steels consisting of ferrite
which are comparatively less sensitive to the and pearlite is changed to alpha iron. The weld
atmospheric gases and thicker welding. As the metal in the molten state has a good tendency to
electrode melts, the flux covering disintegrates, dissolve gases which come into contact with it
giving off a vapours that protect the weld area like oxygen, nitrogen and hydrogen.
from oxygen and other atmospheric gases. In The heat affected zone is within the
addition to that molten slag which covers the base metal itself. It has a microstructure different
filler meatal as it is travels from the electrode to from that of the base metal after welding,
the weld pool. Once part of the weld pool, the because it is subjected to elevated temperature
slag floats to the surface and protects the weld for a substantial period of time during welding. In
from contamination as it solidifies. [4] the heat affected zone, the heat applied during
welding recrystallizes the elongated grains of the
1.1 METALLURGY OF A WELDED JOINT base metal, grains that are away from the weld
Metal is heated over the range of metal will recrystallizes into fine equated
temperature up to fusion and followed by cooling grains.[4]
ambient temperature. Due to differential heating,
the material away from the weld bead will be hot 1.2 Dissimilar Metal Welding
but as the weld bead is approached
progressively higher temperatures are obtained,
Joining of dissimilar metals has found its Welding produces large tensile stresses, the
use extensively in power generation, electronic, maximum value of which is approximately equal
nuclear reactors, petrochemical and chemical to the yield strength of materials that are joined
industries mainly to get tailor-made properties in by lower compressive residual stresses in a
a component and reduction in weight. However component.
efficient welding of dissimilar metals has posed After welding a residual tensile stress
a major challenge due to difference in thermo- remains across the weld centerline and causes
mechanical and chemical properties of the a balancing compressive stress further from the
materials to be joined under a common welding weld zone. The tensile residual stress on the
condition. This causes a steep gradient of the weld line reduces the fatigue strength and the
thermo-mechanical properties along the weld. toughness, particularly when combined with any
A variety of problems come up in notches or defects associated with the weld
dissimilar welding like cracking, large weld bead.
residual stresses, migration of atoms during To relieve some of the residual stresses caused
welding causing stress concentration on one by the welding process, the structure deforms,
side of the weld, compressive and tensile causing distortion. There are several modes of
thermal stresses, stress corrosion cracking, etc. distortion, but the one that is most common,
Now before discussing these problems coming particularly in thin welded structures is buckling
up during dissimilar welding, the passages distortion, which is caused by the compressive
coming below throw some light on some of the stress in the parent material.
causes of these problems.
In dissimilar welds, weldability is 1.3.2 Thermal Stresses
determined by crystal structure, atomic diameter
In dissimilar metal welding, one of the
and compositional solubility of the parent metals
metals in contact at the weld metal interface is
in the solid and liquid states. Diffusion in the
constrained by expansion or contraction of the
weld pool often results in the formation of
other. The two metals being welded possess
intermetallic phases, the majority of which are
different coefficient of thermal expansion. The
hard and brittle and are thus detrimental to the
metal having a higher coefficient of thermal
mechanical strength and ductility of the joint.
expansion, with its tendency to expand more
The thermal expansion coefficient and
than the other is constrained by the fixed
thermal conductivity of the materials being
boundary.
joined are different, which causes large misfit
As a result of which compressive
strains and consequently the residual stresses
thermal stress is developed in the metal having
results in cracking during solidification. [8]
a higher coefficient of thermal expansion while
tensile thermal stress is developed in the metal
1.3 Stresses in Welded Joints
with the lower coefficient of thermal expansion.
The stresses in welded joints are difficult to The thermal stress developed during the welding
determine because of the variable and is shown in fig
unpredictable parameters like homogeneity of
the weld metal, thermal stresses in the welds,
changes in physical properties due to high rate
of cooling, etc. In design problems, these
stresses are obtained on the following
assumptions:
1. The load is distributed uniformly along the
entire length of the weld, and
2. The stress is spread uniformly over its
effective section.

1.3.1 Residual Stress


Residual stress is a tension or
compression that exists in a material without any Figure 3. Stress in welds (a) thermal stress during &
external load being applied, and the residual (b) residual stress after welding.
stresses in a component or structure are caused 1.3.3 Thermal Stress Superimposed under
by incompatible internal permanent strains. Residual Stress
The welded metal parts are subjected to Two dissimilar metals stainless steel
a numerous cycles of thermal expansion and and carbon steel is selected for the
contraction. As result of which these thermal experimentation. And Shielded Metal Arc
stresses get superimposed over the residual Welding is used to weld this two dissimilar
stress induced after welding. metals. Samples were sent to the TCR Testing
A correct estimate of thermal stresses under Laboratory, Baroda, and Gujarat, India for
superimposed condition with the residual stress chemical composition and grade testing.
is necessary to determine the weakest zone or From the results it was found that the
the area most susceptible to cracking. The cyclic stainless steel has ASTM A 240 GRADE 304
thermal stresses superimpose on the weld material grade and Carbone steel has IS 2062
residual stress and operating tensile stresses GRADE A.
can promote brittle fracture, increase the
Table 1. Chemical composition of Carbon Steel
susceptibility of a weld to fatigue damage and
stress corrosion cracking (SCC) during service.
This will ensure a sound design of the joint and Element Result
structural integrity.
C (%) 0.069
2. OBJECTIVE
2.1 Need of Measuring Residual Stress:
S (%) 0.005
The term residual stress refers to the stress that
exists in a weldment after all external load have
been removed. Various terms have been used P (%) 0.016
to describe residual stress, this includes internal
stress, initial stress, inherent stress, reaction
stress and locked in stress. Residual stress Mn (%) 0.620
occurs when a structure is subjected to non-
uniform temperature change. Introduction of Si (%) 0.045
residual stress in welded joint may cause
Cracks, Distortion, Peen forming, Fretting,
Stress corrosion cracking, Crack initiation and Table 2 Chemical Composition of Stainless Steel
propagation.
2.2 Benefits of measuring and monitoring Element Result
residual stress:
 Optimize process parameters such as
C (%) 0.024
measuring the effectiveness of peening on a
part at critical location.
 Provide a quantitative metric to enable S (%) 0.007
specification and go/no go decision.
 Improve product quality, substantiate supplier P (%) 0.033
quality.
 Improve safety and catastrophic failures. Mn (%) 1.61
 Validate repair area has been restored to
original. SI (%) 0.434
 Residual stress information can improve the
probability of detection of other nondestructive
Cr (%) 18.1
techniques.
 Validate residual stress distribution from FE
models and or fracture mechanical Ni (%) 8.24

3. EXPERIMENTAL PROCEDURE
3.2 Welding Procedure
3.1 Parent Metal
Plates of dimensions (100 × 150 × 4)
mm were cut from a large sheet of the mild steel
and finished by machining. In order to perform Table 4 Taguchi L9 array design for Experiments
welding operation the finished plates were again
cut transversally into equal halves of (1×125×15) Sample Voltage Current Time Length Speed Weld
mm for groove preparation as required in the No (V) (A) (Sec) (mm) mm/min Pass
present study. Before welding, the plates’
surfaces were cleaned, thoroughly using both 65.2 150 136.6 Root
chemical and mechanical processes. This was 20 to
S1 75 78.2 150 115.1 Pass 1
done to remove any types of contaminations, 22
which may results from oil, grease, corrosive 66.0 150 136.4 Main
products etc. to obtain a good quality weld [8]. 49.3 150 182.5 Root
20 to
Table 3. Detailed welding parameter descriptions S2 75 62.9 150 143.1 Pass 1
22
65.3 150 137.8 Main
Weld Layer(s) Initial Rest 40.6 150 221.7 Root
20 to
Process GTAW SMAW S3 75 49.0 150 183.7 Pass 1
22
309L- 47.0 150 191.5 Main
Filler lass R 309L
16,17
Metal 65.3 150 137.9 Root
Dia.(mm) 2/2.4 2.5/3.2 20 to
Type DC DC S4 90 77.6 150 116.0 Pass 1
Current 22
Polarity EN P 64.0 150 104.6 Main
(A)
Amp. Range 60-110 60-100 54.8 150 164.2 Root
Volt Range (V) 10-15 20-30 20 to
S5 90 60.2 150 149.6 Pass 1
Speed 22
Travel 4-6 4-10 61.0 150 147.6 Main
(cm/min.)
45.6 150 197.4 Root
The welding of two dissimilar metal is done 20 to
S6 90 44.2 150 203.8 Pass 1
according to welding producer specification by 22
45.8 150 196.7 Main
using SMAW welding. SS309L is used as the
welding electrode. 47.2 150 190.6 Root
20 to
S7 105 64.2 150 140.3 Pass 1
22
52.0 150 173.1 Main
51.8 150 173.7 Root
20 to
S8 105 61.9 150 145.4 Pass 1
22
50.0 150 180.0 Main
27.4 150 328.3 Root
20 to
S9 105 40.2 150 223.8 Pass 1
22
33.5 150 268.7 Main

Figure 4. Welding of Plate 4. RESULTS AND DISCUSSION

4.1 Radiography Test

After welding it is necessary to check the


acceptability of the joint for industrial Usage of
the welded joint. Radiography will give each and
every defect that exist in the welded plate. It
provides the idea about whether the welded joint
is acceptable or not. Also this would help to
select good weld section out of whole for the
specimen for Residual stress measurement.

Figure 5. Radiography of Samples


4.1.1 Result of radiography test
Table 5. Results of radiographic test
Sr
Job Observation Result
no.

1. S1-S-75-SMAW Poro/c.i Acceptable

2. S1-S-75-SMAW Poro Acceptable

3. S1-S-75-SMAW c.i/poro Acceptable


Figure 6. Test Specimen S3 Base Metal & HAZ
4. S2-S-90-SMAW Poro Acceptable

5. S2-S-90-SMAW Poro Acceptable

6. S2-S-90-SMAW Poro Acceptable

7. S3-S-105-SMAW Poro/uc Acceptable

8. S3-S-105-SMAW Poro Acceptable


Figure 7. Metallography of S5 & S8
9. S3-S-105-SMAW Ntg Acceptable
4.2.2 Discussion
 For metallography structure, Specimens are
4.1.2 Discussion prepared on the diamond polishing machine
 According to WPS (ASME SECTION IX) and applied etchant as Nital for carbon steel
parameter we have done RT (Radiographic material.
Test) for welding joint of dissimilar metal of  Form the AWS books, carbon steel have high
carbon steel to stainless steel welding joint. heat transfer rate compare to stainless steel
 All the parameters are selected from the material Because of the high heat transfer
WPS and found out Heat input for all 9 rate, change in structure formation is fast in
specimen. the CS.
 For Minimum to Maximum heat input  Due to the increase in heat input, martensitic
condition, all the Radiography test results needles increase in the carbon steel material
are cleared out and all are acceptable.

4.2 Metallography test 4.3. Residual stress measurement test


4.2.1 Results 4.3.1 Result
Specimen are prepared for residual
stress test on wire cut EDM machine and send
the sample at IIT Bombay for the
experimentation. Residual stress measured with
help of XRD (X-Ray Diffractometer) testing
machine. Samples are prepared on Wire-Cut
EDM which have a thickness of 4mm and 10mm
x 10 mm width and length of the material and
proper welded and electro-polished surface.
Table 6 Results of residual stress the optimisation of the submerged arc
welding Process”, Int. J. Adv. Manuf.

RESIDUAL RESIDUAL
4.3.2 Discussion STRESS STRESS
SAMPLE
EXPERIMENT ANALYTCAL
 From the results, when there is an increase (MPa) (MPa)
in heat input will increase the residual S1 309.9 626
stress. S2 847 556.1
 Following graph suggest that increase in S3 617 525
heat input will increase the residual stress S4 697 557
S5 710 542.8
S6 516 532
S7 283.1 555.8
S8 402.2 547.5
S9 203.8 502
Technol. 16 (2000) 688–694.
[3] S. P. Tewari, ankur gupta , jyoti prakash
,2010. “effect of welding parameters on the
weldability of material”.international journal
of engineering science and technology, vol.
2(4), 2010, 512-516
[4] Welding Journal, Vol. 42(1), pp.38-46.
[5] O P Khanna (2001), “A Text Book of
Figure 7. Residual stress vs Heat Input Graph
Welding Technology”, Dhanpat Rai
Publications, pp. 570-577.
5. CONCLUSION [6] S. Sabooni, F. Karimzadeh, M.H. Enayati, et
al., Friction-stir welding of ultrafine grained
 Residual stresses in restrained welds and
austenitic 304L stainless steel produced by
weld repairs are very complex. The heat input
martensitic thermomechanical processing,
affects the value and distribution of residual
Mater. Des. 76 (2015) 130–140.
stress in the specimen. This peak stress in all
[7] W.Wu, S. Hu, J. Shen, Microstructure,
samples occurred not at the toe, but in the
mechanical properties and corrosion
middle of the weld bead, where the yield
behaviour of laser welded dissimilar joints
stress is higher. From the results, As the Heat
between ferritic stainless steel and carbon
Input is increase, there is an increase in the
steel, Mater. Des. 65 (2015) 855–861.
residual stress.
[8] L.-E. Svensson: Control of microstructure
 From the above results and discussion, It is and properties in steel arc welds, CRC
concluded that, carbon steel has higher heat Press, Inc., 1994
transfer rate compare to stainless steel, due to [9] Deng D, Liang W, Murakawa H.
that reasons all the properties likes change in Determination of welding deformation in fillet
thermal expansion, metallography structure, welded joint by means of numerical
thermal conductivity and cooling rate is simulation and comparison with experiment.
occurred in the carbon steel is fast compare [10] Mater Sci Eng a 2008; 487:210–8. Deng D.
to stainless steel. FEM prediction of welding residual stress
and distortion in carbon steel considering
6. REFERENCES phase transformation effects. Mater Des
2009. ;30: 66
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