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CUTTING DUCTILE
IRON PIPE
®
FIELD WELDING AND
CUTTING DUCTILE IRON PIPE
By Richard W. Bonds, P.E.
Research and Technical Director
D
UCTILE IRON PIPE MANU- As with any base material, the suc-
FACTURERS have been suc- cess of welding Ductile Iron depends
cessfully welding Ductile Iron on suitable equipment, correct proce-
pipe for many years and should dures, qualified welders, and effective
be consulted on their recommendations quality control procedures.
for field welding and torch cutting their
product. The Ductile Iron Pipe Research
Association (DIPRA) does not support Ductile Iron Pipe
indiscriminate field welding of Ductile
Iron pipe. However, unforeseen circum- The first Ductile Iron pipe was cast exper-
stances might require field welding of imentally in 1948. Years of metallurgical,
retainer rings, thrust collars, etc., onto casting, and quality control refinement
the barrels of Ductile Iron pipe. followed, and in 1955 Ductile Iron pipe
This manual is intended as a guide for was introduced into the marketplace.
field welding and cutting cement-mortar- Its phenomenal strength and impact
lined and unlined Ductile Iron pipe. For resistance compared to Gray Iron, along
Ductile Iron with many other advantages, created a
welding or cutting special lined pipe,
consult the pipe manufacturer. rapid increase in demand for this prod-
The procedures described are intend- uct as engineers and utility officials real-
ed to be used only by qualified welders ized that it could be transported,
having adequate skill and experience in handled, and installed with virtually no
the practice of the appropriate welding damage to the pipe. In service, Ductile
and cutting methods for cast ferrous Iron pipe showed that expense of repair
materials. Only such qualified welders was practically eliminated.
should be allowed to field weld and field Ductile Iron is usually defined as a
cut restrained joints for Ductile Iron pipe. Cast Iron with primary graphite in the
Pipe manufacturers’ recommended pro- nodular or spheroidal form. This change
cedures shall be followed while exercis- in the graphite form is accomplished by
ing reasonable care. Care should also be adding an alloy, usually magnesium, to
exercised in the application of the princi- molten iron of appropriate composition.
ples contained herein. DIPRA assumes Properly treated iron will solidify with
no responsibility and disclaims liability the graphite in the form of nodules or
for the design or performance of pipe spheroids. The distribution and shape
joints or pipe systems fabricated with this of the graphite nodules are set when the
approach. Also, DIPRA assumes no metal solidifies in the mold and will
responsibility and disclaims liability for remain essentially unchanged during
injury or damage to persons or property Gray Iron subsequent processing. Because of the
arising from the use of these procedures. mold cooling and rapid iron solidifica-
tion, the pipe must be annealed (heat
treated) to produce the necessary pro-
Introduction portion of ferrite that imparts strength,
ductility, and impact properties required
As these photomicrographs show, Ductile
Welding is a very important fabrication Iron differs from Gray Iron in that its by specifications for water service.
method in modern industry. If an alloy graphite is spheroidal, or nodular, instead of The annealing treatment relieves cast-
can be welded successfully, its usefulness the flake form found in Gray Iron. Ductile’s ing stresses and produces the microstruc-
is clearly enhanced. Ductile Iron can be greater strength, ductility, and toughness tural transformation that increases the
welded successfully to produce welds are due to this change in microstructure. toughness and improves ductility of the
2 Copyright © 1998, 1992 by Ductile Iron Pipe Research Association
The annealing treatment for Ductile Iron pipe relieves casting stresses and produces the microstructural transformation that increases
the pipe’s toughness and improves the ductility of the iron while maintaining the required strength.
iron while maintaining the required irons have a common factor affecting Preparation for Welding
strength. The effectiveness of the magne- their weldability. During the welding of The success of any welding operation is
sium treatment of the iron as well as the cast irons, the iron immediately adjacent affected by how effectively the prepara-
annealing treatment of the pipe is proven to the weld metal is heated to its fusion or tion and cleaning operations are carried
by means of physical tests. The types of melting point. After welding, the entire out prior to welding. The welding area
tests, test frequencies, and acceptance heat-affected zone cools very rapidly. on the pipe and connecting piece must
limits that are required are specified in During this heating and cooling, some of be untarnished, dry, and grease-free. It
ANSI/AWWA C151/A21.51 Standard, the graphitic carbon dissolves and diffus- has been found that the asphaltic coating
“Ductile-Iron Pipe, Centrifugally Cast, for es into the iron, and, as a result, carbides on the pipe can most easily be removed
Water.” The acceptance test require- tend to form at the edge of the fusion with a torch. An alternate method is to
ments of the ANSI/AWWA C151/A21.51 zone, and high-carbon martensite and wash and wipe the area with a well-
Ductile Iron Pipe Standard are: bainite tend to form in the remainder of soaked rag containing mineral spirits or
1.Tensile properties of specimens the heat-affected zone. The formation of other solvents. (Safety precautions must
machined from the pipe wall: ulti- these hard, brittle microconstituents be observed when using flammable
mate strength, 60,000 psi minimum; increases the susceptibility to cracking. materials.) After the asphaltic coating
yield strength, 42,000 psi minimum; The lower surface-to-volume ratio of the and any grease, etc., have been removed
elongation, 10 percent minimum. nodular graphite in Ductile Iron as com- from the weld area, the area should be
2.Charpy V-Notch impact strengths pared to that for the flake graphite in ground to bright metal to remove all
on specimens cut from the pipe Gray Iron results in less carbon dissolu- annealing oxide. Also, the correspond-
wall: 7 ft-lb minimum at 70°F; tion and the formation of fewer carbides ing surface of the Ductile Iron or alloy
3 ft-lb minimum at -40°F. and less high-carbon martensite. steel connecting piece to be welded
Ferritic Ductile Iron, as compared to Also, because of its localized nature, should be cleaned and ground to bright
Gray Iron, will have about twice the welding produces thermal stresses in metal. A shot-blasted surface alone is
strength as determined by a tensile test, the weld area. Ductile Iron pipe, having not adequate for welding.
beam test, ring bending test, and burst- a predominantly ferritic matrix, is capa-
Weld Joint Design
ing test. The tensile elongation and ble of local plastic deformation to accom-
Most weld joint designs commonly used
impact strength of Ductile Iron are modate these welding stresses and is
for welding carbon steels are generally
many times that of Gray Iron. therefore better suited to absorb weld-
suitable for welding Ductile Iron (butt
ing stresses than is Gray Iron. Success-
welding is not recommended).
General Welding of Iron ful welds can be made by minimizing
the stress from contraction of the weld Preheating
Pipes metal as it cools, the pick-up of carbon Preheating involves raising the tempera-
by the weld metal, and by controlling ture of the base metal in the region to be
Weldability of Ductile Iron
the rate of cooling. welded to a predetermined temperature
Due to their high carbon content, all cast
prior to carrying out the welding
3
process. Preheating may be applied to (ERNi-CI) and (ENiFe-CI) respectively. Welding Procedures
help prevent cold-cracking, reduce hard- These electrodes are capable of produc- Welding current for a particular electrode
ness in the heat-affected zone, reduce ing suitable welds without preheating or size should be within the range recom-
residual stresses, and reduce distortion. postheating the pipe or connecting mended by the manufacturer but as low
Normally, preheating of Ductile Iron piece. Nickel-iron electrodes are avail- as possible, consistent with smooth oper-
pipe is not necessary and is impractical to able from most of the leading electrode ation, desired head contour, and good
do in the field. However, in extreme cold manufacturers and, although composi- fusion. When used in other than the flat
weather one may find it advantageous to tion with reference to nickel and iron horizontal position, an electrode recom-
warm the pipe weld area with a torch. content remains broadly the same, dif- mended for out of position welding, such
ferences in slag-stripping qualities and as Inco Alloys International’s Ni-Rod 55X,
Shielded Metal-Arc Welding
operation may be found in electrodes should be used. The welding current
Shielded metal-arc welding is the most
obtained from different sources. Two should be reduced 10 to 20 amps for verti-
common welding process used on Duc-
nickel-iron electrodes are Inco Alloys cal welding and 5 to 15 amps for overhead
tile Iron pipe in the field. The equip-
International’s Ni-Rod 44 and Ni-Rod 55. welding with Inco Alloys International’s
ment necessary for shielded metal-arc
Mild-steel, arc-welding electrodes are Ni-Rod 55X. The arc length should be
welding is as follows:
not recommended for use with Ductile kept as short as possible consistent with
1.D.C. arc welder using reversed
Iron because of the high risk of cracking obtaining smooth operation and sufficient
polarity.
at the interface of weld and base metal. penetration and wash at the side of the
2.Suitable welding electrodes.
Deposited metal from the ENiFe-CI joint. A slight weave of the electrode is
3.Welding cable, work-piece cable,
electrode has a carbon content well recommended, although this should not
electrode holder, gloves, shield
above the solubility limit. The excess exceed three times the diameter (i.e.,
and protective clothing.
carbon is rejected as graphite during corewire diameter) of the electrode.
Electrodes for metal-arc welding are solidification of the weld metal. This When mild-steel components are being
normally covered with a flux coating. reaction causes an increase in volume joined to Ductile Iron pipe, the center line
The coating can fulfill the following that tends to minimize weld shrinkage of the arc should be concentrated as far
functions: during solidification. This, in turn, as possible onto the mild-steel compo-
1.Stabilize the arc by ionization. reduces residual stresses in the weld nent, which is thereby made to absorb as
2.Provide protection for the molten metal and the iron’s heat-affected zone. much heat as possible from the arc. The
metal from the atmosphere by relatively low arc intensity associated with
Care of Electrodes
evolution of gases such as carbon the nickel-iron electrodes, coupled with
Electrodes must be completely free from
dioxide and by hydrogen and also the sluggish metal-transfer characteristic,
moisture when used. Porosity in the
by the formation of a protective is conducive to minimum heat input, giv-
weld can and often does originate
slag or flux. ing minimum fusion and minimum car-
because of moisture pick-up by the elec-
3.Influence the properties of the bide formation in the base iron.
trode coating. It is invariably due to the
weld metal by de-oxidation and By depositing narrow beads in short
fact that the electrodes have been stored
alloying. lengths one can reduce the cumulative
in unsatisfactory conditions. Ideally, elec-
4.Control the arc characteristics. effect of the stresses from shrinkage of
trodes should be stored in an oven main-
weld metal. Each length of bead should
Recommended Electrodes tained at a temperature of at least 250°F.
be allowed to cool until it can be touched
Some electrodes recommended for If they have not been stored under these
by hand before another deposit is made
welding Ductile Iron are the 44- and 55- conditions they should be baked for at
within the area heated by the first bead.
percent nickel-iron electrodes. Consult least 1 hour at 480°F in a well-ventilated
While one bead is cooling, others are
pipe manufacturer for recommenda- electric oven prior to use. The practice of
deposited at other locations throughout
tions. These electrodes provide weld drying electrodes by shorting them out is
the joint. All beads should be deposited
metal strength and toughness properties not recommended. Excessive heating by
in the same direction.
that are comparable to those of the base this method, apart from having adverse
Another method to reduce shrinkage
iron. The 44- and 55-percent nickel-iron effects on the power source, can damage
stresses is to peen a deposited bead of
electrodes should be in conformance the coatings and thus reduce their shield-
weld metal while it is still hot. Peening
with class designation AWS A5.15 ing efficiency when used.
4
Figure 1 Shielded Metal-Arc Welding Process
5
derives its protection from the slag
formed from the flux materials contained
Figure 3 Flux-Cored Wire Arc Welding Process
in the core of the tubular wire. A Ni-Rod
FC55 cored wire electrode is available
that produces weld metal with a compo-
sition and micro-structure similar to that
deposited by ENiFe-CI covered elec-
trodes. The principle of graphite precipi-
tation and the associated volume
increase is the same for both electrodes.
The flux-cored electrode is a self-
shielding design but it may be used with
carbon dioxide (CO2 ) shielding or as a
submerged arc welding electrode. The
electrode producer should be consulted
for recommendations on usage and pro-
cedures for specific applications.
Oxyacetylene Welding
Oxyacetylene welding procedures
require large amounts of heat input dur-
ing both the pre-heating and the welding
operations. The extensive heating is a
limiting factor in the application of this
process. The process is not considered
suitable for fabrication work as the high
heat input can cause excessive distor-
tion; and in the as-deposited condition,
the weld area is likely to contain a high sections of the pipeline. However, if field various diameter electrodes are shown in
proportion of iron carbide. cuts are required in restrained joint pipe Table 1 below.
sections utilizing the welded-on retainer The weld electrodes used should be in
ring, a loose factory-supplied ring can be conformance with Class designation AWS
Field Welding Procedure field-welded onto the barrel of the field-
cut Ductile Iron pipe.
5.15 (ENiFe-CI). Three such electrodes
are Inco Alloys International’s Ni-Rod 44,
For Field-Cut Restrained Welds should be applied using a D.C.
arc welder employing reversed polarity
Ni-Rod 55 and 55X (consult pipe manu-
facturer for recommendations). The
Joint Ductile Iron Pipe and operating at amperage ranges recom- electrode and electrode diameter recom-
mended by the electrode manufacturer. mended by pipe manufacturers for their
Many restrained joint designs rely on a
General ranges of amperages for retainer ring should be used.
welded-on retainer ring around the spigot
of the pipe to provide part of the means of
restraint. This retainer ring is furnished
Table 1 General Amperage Ranges for Various Electrodes
factory-welded in position on the pipe. Electrode Diameter Recommended Current (amp)
The welding is performed by welders 3/32-in. 40-65
qualified to produce high-quality, depend-
1/8-in. 75-95
able welds. By planning ahead, neces-
sary field cuts of Ductile Iron pipe can 5/32-in. 100-135
normally be positioned in unrestrained 3/16-in. 120-155
6
Step 1. Measure the pipe diameter (or circumference) at the location of the cut to
Procedure
ensure that it is within the tolerance shown in Table 2 on page 11 of this brochure.
1. Measure the candidate pipe diame-
ter (or circumference) at the loca-
tion of the cut to be made to
ensure that the pipe diameter and
circumference are within the toler-
ance shown in Table 2. (Note:
There are minimum laying lengths
for restrained joint pipe. Consult
manufacturer.)
11
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