Experience from the workshop! Weld recommendations for high strength steels Mikael Reinberth, Sr Specialist, Joining and Thermal Cutting Technology General aspects All conventional welding methods can be used Can be welded to all weldable steels Heat input/t8/5 should be controlled Max. heating temperature: ► ► ► ► ► ► ► Dx 355 - 700 Dx 900 - 960 Dx 1100 Wx 460 - 700 Wx 960 Wx 1100 Wx 1300 650ºC 400ºC 200ºC 580ºC 550ºC 200ºC 200ºC Filler material Rm (MPa) Recommended strength of welds subjected to high stresses 1100 1000 MAG MAG (Solid wire) (FCAW) (MCAW) A5.5 E 120X A5.28 ER120S-X A5.29 E12XT-X A5.28 E120C-X A5.23 F12X A5.5 E 110X A5.28 ER110S-X A5.29 E11XT-X A5.28 E110C-X A5.23 F11X A5.5 E 100X A5.28 ER100S-X A5.29 E10XT-X A5.28 E100C-X A5.23 F10X A5.5 E 90X A5.28 ER90S-X A5.29 E9XT-X A5.28 E90C-X A5.23 F9X A5.5 E 80X A5.18 ER80S-X A5.29 E8XT-X A5.28 E80C-X A5.23 F8X A5.5 E 70X A5.18 ER70S-X A5.29 E7XT-X A5.28 E70C-X A5.23 F7X (solid wire/flux combinations) Domex 960-1100, Weldox 960 - 1300 Domex 650 – 700 MC, Weldox 700 Domex 550 – 600 MC 900 Domex 500 MC HARDOX Domex Domex 220 - 460 MC Recommended strength of all other welds SAW MAG MMA 800 700 600 500 8 Recommended t8/5-intervals Requirement: min. 27 J at -40ºC Steel grade Recommended t8/5 intervals Weldox 700 5 – 25 s Weldox 900 5 – 20 s Weldox 960 - 1300 5 – 15 s Domex 355 – 500 MC 2 – 25 s Domex 550 – 700 MC 2 – 10 s Domex 900 - 1100 t8 / 5 5 – 15 s Q 2 1 4300 4 ,3 T0 10 2 d 500 T0 5 1 1 t 8 / 5 6700 5 T0 Q 500 T0 800 T0 Q = Heat input (kJ/mm) d = Single plate thickness (mm) T0 = Working temperature (ºC) F2 = Shape factor F3 = Shape factor 2 1 800 T0 2 F2 F3 Use WeldCalc to calculate and optimize the weld procedure Max interpass temperature Steel Grade Temperature (ºC) Weldox 700 - 960 300 Weldox 1100 - 1300 200 Domex 700 MCE 100 Domex 900 - 1100 200 Static strength of high strength joints Weldox 700 Rp0,2 [Mpa] 700-780 Rm [Mpa] 780-830 Base material / HAZ Weldox 900 780-850 940-1000 HAZ / Weld metal Weldox 960 900-980 1000-1050 HAZ / Weld metal Weldox 1100 950-1030 1010-1090 HAZ / Weld metal Weldox 1300 1000-1100 1100-1200 HAZ / Weld metal Domex 700 700 - 780 760 - 850 Base material / HAZ Domex 960 960 - 1070 1020 - 1140 HAZ / Weld metal Domex 1100 950 – 1070 1010 - 1180 HAZ Steel grade* Typical location of fracture Weldox – hardness profile Weldox 700, 900, 960 Weldox – hardness profile Weldox 1030, 1100, 1300 Hydrogen crack Formed at low temperatures (< 200 °C) Located in the HAZ or in the weld metal Three different parameters has to coincide in order to obtain hydrogen cracks: Brittle microstructure Hydrogen Filler metal Plate surface Atmosphere (1 – 2ml/100g) Tensile stresses Hydrogen crack in HAZ Min. preheat temp. for Weldox The table below is valid for heatinputs of 1.7kJ/mm or higher For heat inputs between 1.0-1.6 kJ/mm. Increase the the preheat temperature with 25°C for cases where elevated preheat temperatures are required. For heatinputs lower than 1.0 kJ/mm use WeldCalc or EN 1011-2 *Consumable determine the preheating temperature if its carbon equivalent + 0.03 is higher than that of the plate Joint preparation ► Machining ► Milling ► Thermal cutting ► Flame cutting ► Laser cutting ► Plasma cutting Type of joints 28 Joint configurations For thicker plates changes in the mechanical properties in the center line is more pronounced. As a consequence, unsymmetrical joints are beneficial for enhanced resistance to hydrogen cracks Factors Affecting the Fatigue Strength in Welded Joints Load Due to residuals stresses t Load Stress peaks Butt weld Slaggs, inclusions, Cold laps, undercut, etc How to Improve Fatigue Strength in Welds Create compressive residual stress Improve to geometry of the weld toe Lower Peaks HFMI in General Cylindrical indenters accelerated against the object Frequency above 90 Hz Material highly plastically deformed HFMI, Tools Example of Welded Joints to Consider Examples of Welded Joints Not Suitable maximum possible improvement, # of FAT classes Proposed Fatigue Strength Improvement Proposal for HFMI treated welds, m=5 8 7 6 5 4 IIW guideline for needle or hammer peening, m=3 3 2 1 0 0 1 2 3 4 235‐355 355‐550 550‐750 750‐950 over 950 fy (MPa) [3] Yildirim, H. C. and Marquis, G. B., Fatigue strength improvement factors for high strength steel welded joints treated by high frequency mechanical impact, , Int J Fatigue, 44, 2012, pp. 168-176. 5 Summary of the Effect of HFMI As welded: 71 MPa at 2 million cycles (independent of steel grade) HFMI Treated: 180 MPa at 2 million cycles, using 960 material Improvement in stress by more than the double – or 105 times longer fatigue life! Limitations Improvement is dependent on the stress ratio (R-value) Thickness between 5 and 50 mm For original FAT-classes 50-90 Maximum stress 0.8 of yield stress Thank You! Thank You!
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