Residual stress measurement in

Dissimilar welding joint

Presented by,
Harshit Desai
 Outline

 Introduction to C.S. to S.S (dissimilar metal) welding

 Residual stress and its measurement
 Method of Experimentation
 Results and Discussion
 Conclusion
 References
 Welding dissimilar metal
 Combination of metals with significantly different
chemical, mechanical, and physical properties can
easily present problem during before and after
welding.
 Solidification characteristics of weld metal also
influenced by relative dilution and composition
gradient.
 Due to different Thermal conductivity and thermal
expansion stresses are induced in joint area which has
to be investigated and evaluated.
 Residual stress

 What is Residual stress ?

The term residual stress refers to stress that exists in a
weldments after all external loads have been removed.
Residual stress occurs when structure is subjected to non
uniform temperature change.
NEED OF MEASURING RESIDUAL
STRESS:

 Residual stress may cause following defects to

welding joints:
• cracks,
• Distortion,
• Peen forming,
• Fretting,
• Stress corrosion cracking,
• Crack initiation and propagation.
 Benefits of Measuring
residual stress

 Optimize process parameters such as measuring the

effectiveness of peening on a part at critical location.

 Provide a quantitative metric to enable specification and

go/no go decision.

 Improve product quality, substantiate supplier quality.

 Improve safety and catastrophic failures.

 Method of welding

 SMAW:
Welding of Dissimilar Metals

IS 2062 GRADE A carbon steel ASTM A 240 GRADE 304

stainless steel
 Material Grade selection

Material grade testing METHOD OF

EXPERIMETATION
Welding of material (9 samples)
Combination of three currents with three travel
speed

Radiographic testing of welding joint

Sample preparation for Metallography and testing

Sample cutting for residual stress measurement and

testing

Simulation of residual stress

Result and Discussion

Material grade testing in NABL
certified lab

Chemical composition of CS (IS 2062 GRADE A. )

C (%) S (%) P(%) Mn(%) Si(%)

Element
Result 0.069 0.005 0.016 0.620 0.045

Chemical composition of stainless steel:

A 240 GRADE 304 )

C(%) S(%) P(%) Mn(%) SI(%) Cr(%) Ni(%)

Elements
Result 0.024 0.007 0.033 1.610 0.434 18.1 8.240
Sample No Voltage (V) Current (A) Time (Sec) Length (mm) Speed (mm/min) Weld Pass
65.2 150 136.6 Root
S1 20 to 22 75 78.2 150 115.1 Pass 1

66.0 150 136.4 Main

49.3 150 182.5 Root

S2 20 to 22 75 62.9 150 143.1 Pass 1

65.3 150 137.8 Main

40.6 150 221.7 Root

S3 20 to 22 75 49.0 150 183.7 Pass 1

47.0 150 191.5 Main

65.3 150 137.9 Root

S4 20 to 22 90 77.6 150 116.0 Pass 1

64.0 150 104.6 Main

54.8 150 164.2 Root

S5 20 to 22 90 60.2 150 149.6 Pass 1

61.0 150 147.6 Main

45.6 150 197.4 Root

S6 20 to 22 90 44.2 150 203.8 Pass 1

45.8 150 196.7 Main

47.2 150 190.6 Root

S7 20 to 22 105 64.2 150 140.3 Pass 1

52.0 150 173.1 Main

51.8 150 173.7 Root

S8 20 to 22 105 61.9 150 145.4 Pass 1

50.0 150 180.0 Main

27.4 150 328.3 Root

S9 20 to 22 105 40.2 150 223.8 Pass 1

33.5 150 268.7 Main

 Radiography of welding

 In radiography testing the test part is placed between the

radiation source and film(or detector).The density and
thickness differences of the test-part will attenuate the
penetrating radiation through interaction processes
involving scattering and/or absorption.
 Why Radiography is done on
welded joint ?

 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 weather the
welded joint is acceptable or not. But we have done this to
get good weld section out of whole for the specimen for
Residual stress measurement.
Result of radiographic testing
Sample cutting
 Result of radiographic testing
Sr no. Job Observation Result

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

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

9. S3-S-105-SMAW - Acceptable
 Cutting of sample was done by EDM wire cutting machine.

 In wire electric discharge machining , or wire-cut EDM, a

thin single-strand metal wire is fed through the work piece,
typically occurring while in a submerged tank of dielectric
fluid or deionized water. This fluid helps to cool the
process and flush away the cut material.
 Metallography test

Test Specimen S3 Base Metal & HAZ Metallography of S5 & S8

Tensile test
 Tensile test result
Report no. Specimen U.T.S(N/mm2) Fracture

N-09780.1 S1 523 At P.M MS Side

N-09781.1 S2 537 At P.M MS Side

N-09782.1 S3 524 At P.M MS Side

N-09783.1 S4 510 At P.M MS Side

N-09784.1 S5 531 At P.M MS Side

N-09785.1 S6 527 At P.M MS Side

N-09786.1 S7 517 At P.M MS Side

N-09787.1 S8 528 At P.M MS Side

N-09788.1 S9 536 At P.M MS Side

All the failure has occurred at C.S. plate.

 Residual stress Measurement

 X-Ray Diffraction Method @IIT, Bombay

 Residual stress samples

 sample preparation for measurement of residual stress:

 Sample size: 4mm* 10mm *10mm
 Result and Discussion

experimentally
900

800

700

600
residual stress

500

400

300

200

100

0
0 200 400 600 800 1000 1200 1400
heat input
 Simulation study: (meshing of two metals)
Residual stress analysis
 Simulation result
ANALYTICAL
700

600

500
RESIDUAL STRESS

400

300

200

100

0
0 200 400 600 800 1000 1200 1400
HEAT INPUT

Simulation study residual stress suggest increase the

residual stress.
 Result of Residual stress
SPESCIMEN RESIDUAL STRESS RESIDUAL STRESS
EXPERIMENTALLY simulation (MPa)
(MPa)

S1 309.9 626

S2 847 556.1

S3 617 525

S4 697 557

S5 710 542.8

S6 516 532

S7 283.1 555.8

S8 402.2 547.5

S9 203.8 502

Simulation study and experimental study of heat input vs

residual stress suggest the same as increase in heat input
will increase the residual stress.
 Conclusion
 We also concluded that for tensile test, material failure
through the weld material from carbon steel side, and with
the increase of heat input, tensile strength decreases.
 From the residual test data we have concluded that if
experimental data is near about to the simulation analysis
data for that we can avoid the experimentation every time
for the same parameter and also we can predict the
amount of stress produced in the weld area. And also we
found that As the heat input increases residual stress also
increases.
 We recommend metallography in case of high heat input in
dissimilar metal as martensite needle were found in high
heat input case.
 References

 S. Sabooni, F. Karimzadeh, M.H. Enayati, et al., Friction-stir welding of

ultrafine grained austenitic 304L stainless steel produced by martensitic
thermomechanical processing, Mater. Des. 76 (2015) 130–140.

 W.Wu, S. Hu, J. Shen, Microstructure, mechanical properties and

corrosion behaviour of laser welded dissimilar joints between ferritic
stainless steel and carbon steel, Mater. Des. 65 (2015) 855–861.

 WPS (ASME SEC-IX)

 Mater Sci Eng a 2008; 487:210–8. Deng D. FEM prediction of welding

residual stress and distortion in carbon steel considering phase
transformation effects. Mater Des 2009. ;30: 66