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Code of Practice: Normalisation Renault Automobiles Service 65810 Section Normes Et Cahiers Des Charges
Code of Practice: Normalisation Renault Automobiles Service 65810 Section Normes Et Cahiers Des Charges
Code of Practice: Normalisation Renault Automobiles Service 65810 Section Normes Et Cahiers Des Charges
90 - 00 - 151 / - - -
VISA RESPONSABLE(S)
NOM :
SERVICE :
DATE :
SIGNATURE :
Pilote(s) technique(s)
N Tl
P. SCHWARTZ
65810
53130
B. NICOL
Responsable du document
Sce
65520
04/09/2001
90 - 00 - 151 / - - -
RENAULT
This document is to be considered as a whole, the parts of which must not be separated
.
RENAULT 2001.
No duplication permitted without the consent of the issuing department.
No circulation permitted without the consent of RENAULT.
FIRST ISSUE
September 2001
---
REVISION
REFERENCED DOCUMENT
RENAULT 2001
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RENAULT
CONTENTS
Page
1. GENERAL INFORMATION ON STAINLESS STEELS
1.1.1. Definitions
1.1.2. Classification
10
10
11
12
2.1. INTRODUCTION
12
13
14
14
15
15
15
18
19
19
2.7.2. Torsion fatigue test on tubes when hot (As per ME-60152-A-009)
19
20
20
20
21
RENAULT 2001
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RENAULT
CONTENTS (continued)
3. WELDING STAINLESS STEELS
23
3.1. REMINDER
23
23
25
25
25
28
28
28
29
30
3.4.1. General
30
30
33
33
33
4.1.2. Metal transfer modes inj the arc. (Pulsed, Lincoln STT, axial spray)
34
36
38
41
41
5. BIBLIOGRAPHY
RENAULT 2001
42
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RENAULT
1.
1.1.1.
Definitions
Stainless steels are iron - chromium alloys with a minimum chromium content of 12 % and which may
contain:
-
alloys such as Ni, Mo, Ti, Nb, Cu , W, Al and for certain Mn, Si, C and N. These alloy elements
are added in different quantities in order to modify and improve certain properties of the stainless
steels.
The most important elements are carbon and nickel which directly influence the micrographic
structure of the steel.
Carbon: It acts by its character - gene (austenitic) and by its competition with the chromium,
element - gene. The carbon, in the presence of a carburigen element such as chromium, may form
carbons and thereby promote intergranular corrosion.
Nickel: In low quantities, maximum 1 %, there is no incidence on the structure of the steels. Beyond 6
to 8 %, there is an effect - gene, which results in the stainless steels remaining austenitic at ambient
temperature T.
1.1.2.
Classification
Insofar as they are essentially iron-based alloys, stainless steels like other steels, are liable to display
different structural conditions: There are three main categories:
-
RENAULT 2001
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RENAULT
-
1.2.
1.2.1.
The basic composition consists of carbon and chromium, a composition that has been balanced to
ensure that the steel is entirely ferritic at high temperature.
These types of steels do not have any transformation point and are practically ferritic at all
temperatures. It follows that they are very sensitive to grain expansion and are therefore brittle when
heated for the purposes of forming, welding and thermal treatment, such effects being cumulative.
In addition, they have the specific characteristic of containing very little austentite at high
temperature; this austentite will therefore be very rich in carbon; if cooling is very slow, it transforms
itself into ferrite; on the other hand, if it occurs too rapidly, it will transform into hard and fragile
martensite at the joints of the ferrite grains.
It is very important to take this characteristic into account when studying welding problems.
The most frequent addition is molybdenum (0,8 to 1,5 %) in order to improve resistance to corrosion;
sometimes, copper is associated with the molybdenum; however be careful, if the quantity of copper
exceeds 0,5 to 1 %, there is a risk of the steel becoming martensitic.
RENAULT 2001
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RENAULT
90 - 00 - 151 / - - -
Titanium, the role of which is to fix the carbon in order to prevent the austentite from being
overloaded in carbon and from transforming into martensite after the welding operation or to
prevent the carbon from combining with Cr, which would promote intergranular corrosion.
Titanium does not prevent grain expansion, however it should be added in a significant quantity.
Ti 10 at 12 *C for stabilization of C.
Ti 4,2 (C + 2N2) for resistance to corrosion without heat treatment after welding.
Niobium (Nb); the role of which is similar to titanium, however which should be added in a higher
quantity.
Impurity
Nitrogen (N2) remains present as an impurity, however if its quantity is too high, it causes fragility
after welding.
In general:
C + N2 0,04.
If this condition is effectively observed, the brittleness after welding is noticeably reduced; in addition,
an improvement in the intergranular corrosion after welding is observed.
The values of the mechanical characteristics are average:
Rm mini = 440 to 490 N/mm 2
R0,02 = 245 to 275 N/mm2.
RENAULT 2001
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RENAULT
1.2.2.
EUROPEAN DESIGNATION
As per NF EN 10088-2
(Nov. 95)
NAME
Previous
designation of
NF A 35573
(Cancellation
Nov. 95)
(Cancellation
Nov. 95)
ASTM
AISI
UNS
Si
Mn
Cr
410S
S41008
0,05
0,35
0,30
12,70
409
S40900
0,02
0,50
0,30
11,50
410S*
S41008
0,02
0,50
0,60
11,00
430
S43000
0,05
0,35
0,40
16,50
0,02
0,35
0,40
16,50
0,05
0,35
0,40
16,50
0,02
0,15
0,40
Mo
16,80
Ni
Other
Rm
Rp0,2
A%
480
330
26
410
250
32
1,4516
510
350
28
F 18 (Cr 17,5)
500
340
26
450
300
30
F 17 MS (Mo = 1,25)
540
370
27
700
360
20
Ti + Nb = 0,700
490
300
30
1,4000
Z8C12
X2CrTi12
1,4512
Z3CT12
Z2CrNi12
1,4003
X6Cr17
1,4016
Z8C17
X3CrTi17
1,4510
Z4CT17
X6CrMo17-1
1,4113
Z8CD17-01
X6CrNi17-1
1,4017
Z8CN17
X2CrTiNb18
1,4509
Z3CTNb18
441
S44100
0,02
0,50
0,50
17,80
X6CrMoNb17-1
1,4526
Z8CDNb17-01
436
S43600
0,04
0,40
0,50
17,50
1,25
Nb = 0,600
520
370
27
X2CrMoTi18-2
1,4521
Z3CDT18-02
S44400
0,02
0,40
0,40
17,70
2,00
Ti + Nb = 0,450
540
380
27
X2CrTi20
1,4604
Z3CT20
0,02
0,20
0,30
20,00
Ti = 0,500
480
320
28
RENAULT 2001
430 Ti**
434
S43400
Ti = 0,180
0,40
Ti = 0,400
1,00
1,40
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RENAULT
+ Mo
Improved
resistance
to corrosion
with pitting
1.4113
Mo : 1,00
Mo : 1,25 Low C
Mo greater
+ Mo, stabilized Nb
Resistance to
corrosion improved
1.4016
17 Cr
C < = 0,10
Low C
Cold forming
Stabilized improved
Ti orNb weldability
Low C
Good resistance
Stabilized to oxidation
Zr or Ti
when hot
or Nb
1.4526
C < = 0,025
Mo : 1,00 + Nb
+ Cr + Al
stabilized Ti
1.4521
C < = 0,025
Mo : 2,00
Ti and Nb
Improved application
(formability,
weldability)
Localized pitting corrosion
, equivalent to316 L
1.4510
C < = 0,030
Ti or Nb
1.4509
Zr or Ti
or Nb
Low C
+ Mo, stabilized
Ti et Nb
Cr : 18
Al : 2,00
Improved
resistance
to corrosion
Reduced C
content
+ Ni + Ti
12 Cr
C < = 0,15
1.4003
C : < = 0,03
Low C content
Improved
weldability
Low C content
Stabilized Ti
RENAULT 2001
Mechanical characteristics
and weldability improved
Mechanical strength
of welded joints (assembly).
1.4000
C < = 0,030
1.4512
C : < = 0,03
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RENAULT
1.3.
1.3.1.
The basic elements of the chemical composition are chromium and nickel:
-
manganese,
silicon,
the possibility of the appearance of ferrite subsequent to thermal effects other than hyperquenching, e.g. the thermal effects due to hot processing and welding. It is important to be able
to determine, beforehand, the ferrite rate liable to occur during a welding operation. This
computation is possible using a Schaeffler diagram (see 3.),
either stabilize the carbon content if such content is greater than 0,03, addition made in order to
protect the metal against the risk of intergranular corrosion:
.
.
2)
3)
4)
RENAULT 2001
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RENAULT
The values of the mechanical characteristics are:
Rm min. = 500 N/mm 2,
R0,02 = 240 to 340 N/mm2.
1.3.2.
EUROPEAN DESIGNATION
As per NF EN 10088-2
(Nov. 95)
NAME
Previous
designation of
NF A 35573
(Cancellation
Nov. 95)
(Cancellation
Nov. 95)
ASTM
AISI
UNS
Si
Mn
Cr
Mo
Ni
Other
Rm
Rp0,2
A%
7,40
800
300
48
6,80
740
320
50
780
360
48
1,4310
Z11CN17-08
301
S30100
0,10
0,60
1,00
17,20
X10CrNi18-8
1,4310
Z11CN18-08
301
S30100
0,10
1,00
1,20
16,80
X2CrNiN18-7
1,4318
Z3CN18-07Az
0,025
0,50
1,50
17,50
6,80
X5CrNi18-10
1,4301
Z7CN18-9
304
S30400
0,05
0,50
1,10
18,20
8,30
670
320
50
X5CrNi18-10
1,4301
Z7CN18-9
304
S30400
0,04
0,50
1,50
18,20
8,70
630
300
52
X5CrNi18-10
1,4301
Z7CN18-9
304
S30400
0,04
0,50
1,50
18,00
9,20
610
270
55
X2CrNi18-9
1,4307
Z3CN18-10
304 L
S30403
0,025
0,50
1,50
18,20
9,20
620
310
50
X2CrNi19-11
1,4306
Z3CN18-10
304 L
S30403
<0,025
0,60
1,50
18,50
10,20
600
300
50
X6CrNiTi18-10
1,4541
Z6CNT18-10
321
S32100
0,03
0,50
1,30
17,50
9,20
610
280
48
X4CrNi18-12
1,4303
Z6CN18-12
305
S30500
0,04
0,60
0,90
18,30
12,20
580
250
52
RENAULT 2001
301 L
0,70
N = 0,15
Ti = 0,300
Ti > 5 (C + N)
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RENAULT
C < = 0,030
17 Cr 5 Ni
8 Mn
N = 0,20
Low C
Improved
weldability
Low C
Low Mn
Low Ni
Increased mechanical
characteristics,
improved weldability
Low C,
low Ni
1.4307
C < = 0,030
Low C
Intergranular
corrosion
1.4404
18-13 MS
C < = 0,03
Mechanical
characteristics
= workhardening
16 Cr 4 Ni
6 Mn
N = 0,15
17 Cr 7 Ni
18 Cr 9 Ni
C < = 0,08
+ Ni
1.4306
Low C
Improved resistance
to intergranular
corrosion
2.
1.4318
18 Cr 7 Ni
1,50 Mn
N = 0,15
+ Mo
Increased generalized
17 Cr 12 Ni
and localized
resistance to
2,00 Mo
corrosion
+ Ni
stabilized Ti
1.4541
or Nb
Intergranular 18 Cr 10 Ni Ti 18 Cr 10 Ni Nb
corrosion
mechanical
characteristics
+ Mo
stabilized Ti 17 Cr 11 Ni
Localized
2,00 Mo
and intergranular
Ti
resistance to
corrosion
CHARACTERISTICS OF MATERIALS FOR EXHAUST LINES (BY DANIEL GOURDET DEPT 64140 - DIMAT - ISSUE OF 08/2000)
2.1.
INTRODUCTION
The purpose of this document is to synthesise the main utilization and implementation characteristics
of metallic materials usually used on exhaust lines.
This information is intended for designers and developers of these types of parts.
The materials mentioned are classified into two families:
-
stainless steels.
RENAULT 2001
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RENAULT
2.2.
Symbol
Designation
Unit
density
kg/dm3
longitudinal elasticity
module
GPa
Remarks
E=
1
1
1 = main stress
1 = corresponding linear variation.
average linear
expansion coefficient
10-6/C
l = lo (l . T)
l = variation in length
lo = initial length
T = temperature variation.
J/kg C
thermal conductivity
W/m C
Rm
tensile resistance
MPa
Rp0,2
conventional elasticity
limit at 0,2 % elongation
MPa
sans
work-hardening
coefficient
sans
Sag-Test
mm
Endurance
characteristic
MPa
RENAULT 2001
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RENAULT
2.3.
Grade
Si
Mn
ES - AS 18/18
0,08
0,04
0,40
ES HT - AS 18/18
0,02
0,10
CS - AS 18/18
0,09
to 0,12
E THT - AS 18/18
Ni
Cr
Mo
Al
Other
0,025 0,025
0,015
0,050
Ti + Nb 0,15
0,40
0,025 0,025
0,015
0,050
Ti 9 x (C + N) - N 0,008
0,05
0,30
0,025 0,025
0,020
0,060
0,02
0,50
0,40
0,020 0,020
0,7
0,60
1,00
X 2 CrTi 12
(1.4512)
0,030
1,0
1,0
0,015 0,040
10,5
12,5
Ti = 6 x (C + N) to 0,65
X 6 Cr 17
(1.4016)
0,080
1,0
1,0
0,015 0,040
16,0
18,0
X 3 CrTi 17
(1.4510)
0,050
1,0
1,0
0,015 0,040
16,0
18,0
X 2 CrTiNb 18
(1.4509)
0,030
1,0
1,0
0,015 0,040
17,5
18,5
X 6 CrMo 17-1
(1.4113)
0,080
1,0
1,0
0,015 0,040
16,0
18,0
0,90
1,40
X 6 CrMoNb 17-1
(1.4526)
0,08
1,0
1,0
0,015 0,040
16,0
18,0
0,80
1,40
N 0,040
7(C + N) + 0,10 Nb 1,00
X 5 CrNi 18-10
(1.4301)
0,07
1,0
2,0
0,015 0,045
8,0
10,5
17,0
19,5
X 6 CrNiTi 18-10
(1.4541)
0,08
1,0
2,0
0,015 0,045
9,0
12,0
17,0
19,0
Ti = 5 x C to 0,70
4 x (C + N) + 0,15 Ti 0,80
Ti = 0,10 to 0,60
3 x C + 0,3 Nb 1,00
The chemical compositions of mild aluminated steels are in conformity with RENAULT Specification
RENAULT 11-04-809/--B.
The chemical compositions of the stainless steels are in conformity with European Standard 10088-1.
2.4.
Grade
Longitudinal elasticity
module
E
(GPa)
Mass
thermal
capacity at
20 C
C
Thermal conductivity
(W/m.C)
(kg/dm3)
20 C
500 C
700 C
200 C
400 C
600 C
800 C
(J/kg C)
20 C
500 C
700 C
32
ES - AS 18/18
7,9
210
170
150
11,5
13,6
14,7
15,3
472
62
40
ES HT - AS 18/18
7,9
210
170
150
11,5
13,6
14,7
15,3
472
62
40
32
CS - AS 18/18
7,9
210
170
150
11,5
13,6
14,7
15,3
472
62
40
32
E THT - AS 18/18
7,9
215
175
155
11,5
12,8
13,7
14,2
472
62
40
32
X 2 CrTi 12
(1.4512)
7,72
215
170
130
11,0
11,5
12,1
12,8
460
26
31
32
X 6 Cr 17
(1.4016)
7,7
205
180
150
10,5
11,5
11,7
12,5
460
26
31
32
X 3 CrTi 17
(1.4510)
7,7
205
180
150
10,5
11,0
12,0
12,8
460
26
31
32
X 2 CrTiNb 18
(1.4509)
7,72
220
190
170
11,0
11,5
12,1
12,8
460
26
31
32
X 6 CrMo 17-1
(1.4113)
7,7
215
190
160
11,7
12,1
12,7
14,2
460
26
31
32
X 6 CrMoNb 17-1
(1.4526)
7,7
215
170
130
11,7
12,1
12,7
14,2
460
30
31
33
X 5 CrNi 18-10
(1.4301)
7,9
200
170
150
17,5
18
19
19,6
500
15
21,5
24
X 6 CrNiTi 18-10
(1.4541)
7,9
200
175
145
17
18
19
19,6
500
14
22,2
23
RENAULT 2001
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RENAULT
2.5.
Grade
Rp 0,2
(MPa)
Rp / Rm
max.
A 1)
(%)
n 2)
(10% Ag)
r 3)
(Ag)
Rm
(MPa)
Rp 0,2
(MPa)
Rp / Rm
max.
A
(%)
44
ES - AS 18/18
280 / 350
160 / 200
0,66
37
0,16
1,4
300 / 370
250 / 310
0,85
ES HT - AS 18/18
300 / 370
180 / 210
0,68
31
0,15
1,3
330 / 380
290 / 340
0,85
42
CS - AS 18/18
380 / 470
270 / 360
0,80
24
400 / 460
300 / 410
0,90
36
E THT - AS 18/18
350 / 450
210 / 270
0,75
28
0,14
1,2
380 / 480
300 / 400
0,90
30
420 / 480
300
30
200
40
X 2 CrTi 12
(untreated) (1.4512)
X2CrTi 12
380 / 450
(annealed) (1.4512)
220 / 300
0,66
30
360 / 450
X 6 Cr 17
(1.4016)
450 / 550
280 / 390
0,70
24
X 3 CrTi 17
(1.4510)
420 / 480
250 / 350
0,70
27
420 / 620
300
30
X 2 CrTiNb 18
(1.4509)
450 / 530
260 / 330
0,66
28
420 / 620
300
30
X 6 CrMo 17-1
(1.4113)
490 / 570
330 / 420
0,70
24
X 6 CrMoNb 17-1
(1.4526)
490 / 560
330 / 400
0,70
27
450 / 580
350
30
600 / 800
500
45
X 5 CrNi 18-10
(1.4301) untreated
X 5 CrNi 18-10
(1.4301) hyperquenched
X 6 CrNiTi 18-10
(1.4541)
250 / 370
0,60
48
500 / 700
205
45
540 / 650
240 / 340
0,60
48
(600 / 800)
( 500)
( 45 )
2.6.1.
Tensile test
2.6.1.1.
Grade
(limit T of utilization
recommendation)
Prop.
20
200
ES - AS 18/18
Rm
330
232
212
192
175
135
(95)
(63)
(650 C)
Rp0,2
185
141
135
118
112
103
(79)
(56)
ES HT - AS 18/18
Rm
335
269
236
219
209
150
88
68
(800 C)
Rp0,2
200
180
165
150
146
110
75
58
CS - AS 18/18
Rm
425
418
392
307
193
144
(86)
(650 C)
Rp0,2
315
235
199
159
119
(77)
E THT - AS 18/18
Rm
395
254
320
299
290
254
218
120
80
61
42
(900 C)
Rp0,2
245
236
228
220
181
163
107
71
57
35
RENAULT 2001
300
400
500
600
700
750
800
850
Page 15/42
90 - 00 - 151 / - - -
RENAULT
2.6.1.2.
Stainless steels
Grade
(T operating limit)
20
Rm
413
Rp0,2 239
1.4512 (annealed) Ag
18,8
X 2 CrTi 12
A
36,3
(820 C)
Z
66
K
772
n
0,21
E
224
Rm
520
Rp0,2 363
1.4510
Ag
21
X 3 CrTi 17
A
25
(830 C)
Z
K
763
n
0,22
E
Rm
460
Rp0,2 260
1.4509
Ag
19,5
X 2 CrTiNb 18
A
33
(920 C)
Z
62
K
803
n
0,2
E
210
Rm
500
Rp0,2 354
1.4526
Ag
19,9
X 6 CrMoNb 17-1
A
30
(920 C) *
Z
63
K
848
n
0,22
E
210
Rm
610
Rp0,2 270
1.4301
Ag
56,9
X 5 CrNi 18-10
A
60
(830 C)
Z
75
K
1759
n
0,57
E
202
Rm
600
Rp0,2 290
1.4541
Ag
50
X 6 CrNiTi 18-10
A
53
(900 C)
Z
65
K
1379
n
0,44
E
202
200
300
400
450
500
550
600
650
700
750
800
850
380
219
348
192
12,9
19,8
68
617
0,21
219
366
225
17,8
28
315
170
290
186
10,9
18,8
73
464
0,16
254
143
218
113
11,8
23,4
71
327
0,13
175
109
92
75
290
186
254
165
210
113
160
116
53
47
3,1
53
87
63
0,04
106
43
41
2
113
39
30
323
198
131
103
5,8
26,4
75
169
0,07
143
105
89
8
68
27
18
3
66,4
93
33,5
0,06
80
22
21
1
149
412
254
622
0,20
422
228
436
262
480
200
480
290
405
208
18,1
25,6
65
695
0,21
181
417
244
14,4
21,3
48
731
0,22
181
450
178
31,4
37,4
49
999
0,40
168
448
287
23,1
30,8
54
884
0,31
168
70
67
139
0,08
383
189
360
172
660
0,22
168
392
232
360
218
659
0,20
168
430
163
410
152
438
272
425
258
867
0,31
162
342
161
13,4
20,5
54
623
0,23
147
330
203
11,8
18,1
47
550
0,18
147
390
149
28,7
38,6
48
853
0,39
153
417
251
21,9
28,3
64
842
0,31
153
322
150
300
182
345
140
400
244
288
132
8,3
16,1
50
612
0,27
134
241
155
9
15,4
54
392
0,17
134
285
132
22,7
44,3
56
526
0,25
147
345
234
16,4
36,1
58
595
0,21
147
31
30
47
0,02
222
122
162
122
240
124
295
220
121
99
3,6
27
83
229
0,21
108
101
92
3,3
61,5
85
120
0,04
108
186
108
17,2
59,3
78
302
0,18
138
239
207
7,7
53,9
73
321
0,09
138
900
950
35
29
26
23
2,8
131,4
94
28
0,03
78
20
19
1,8
105,4
91
31
0,11
78
65
56
16
110,7
69
98
0,14
98
88
88
0,5
52,1
85
104
0,03
98
25
0,01
75
65
70
60
140
95
200
180
43
36
3,5
60,2
94
54
0,07
93
41
39
1,8
88,5
91
47
0,03
93
111
82
10,1
65,2
81
162
0,13
113
159
153
1,8
44
73
184
0,03
113
31
29
88
69
123
120
In bold: test results submitted by UGINE "Exhaust database - Mechanical resistance when hot".
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RENAULT
700
600
500
Rm (MPa)
1.4512
1.4510
1.4509
400
1.4526
1.4301
1.4541
300
200
100
0
0
100
200
300
400
500
600
Test temperature
700
800
900
1000
400
Re ( MPa)
300
1.4512
1.4510
1.4509
200
1.4526
1.4301
1.4541
100
0
0
100
RENAULT 2001
200
300
400
500
600
Test temperature
700
800
900
1000
Page 17/42
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RENAULT
2.6.2.
Sag Test
The Sage Test is an empirical and comparative test consisting in sagging a specimen under its own
weight (flat 25 x 205 mm specimen).
The sag is weighed after 100 h at the same temperature.
2.6.2.1.
Grade
700
750
800
ES - AS 18/18
950
1 000
11
900
ES HT - AS 18/18
850
CS - AS 18/18
E THT - AS 18/18
2.6.2.2.
12
Stainless steels
Grade
700
X2CrTi 12
(1.4512)
750
0,7
800
850
900
950
3 to 6
X 3 CrTi 17
(1.4510)
15
X 2 CrTiNb 18
(1.4509)
0,2 to 1
X 6 CrMoNb 17-1
(1.4526)
2,1
X 5 CrNi 18-10
(1.4301) brut
1 to 3
10 to
15
X 5 CrNi 18-10
(1.4301) hypertr.
RENAULT 2001
1 000
0,6
2,7
4 to 10
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RENAULT
2.7.
2.7.1.
Tube dimensions
Number of
cycles
D 45 x 1,5
2 . 10 6
D 45 x 1,5 (key 6)
2 . 10 5
D 45 x 1,5 (key 6)
2 . 10
D 45 x 1,5 (key 5)
2 . 10 6
D 48 x 1,5 (key 5)
450 C
550 C
650 C
750 C
115
850 C
950 C
60
ES - AS 18/18
ES HT - AS 18/18
CS - AS 18/18
E THT - AS 18/18
2 . 10
133
81
105
80
133
D 45 x 1,5
2 . 10 6
65
(40)
D 45 x 2
2 . 10 6
(170)
100
D 48 x 1,5
2 . 10 5
D 48 x 1,5
2 . 10
D 48 x 1,5
2 . 10 6
160
165
102
48
145
70
2.7.2.
Grades
Diam.
ES - AS 18/18
Test temperature
Dimensions
of tube
Thick.
45 mm
1,5 mm
45 mm
400 C
5
600 C
7
1,5 mm
10
72
10
67
10
62
gradient
10
10
10 7
gradient
44
- 14,41
- 30,28
ES HT - AS 18/18
CS - AS 18/18
62
52
E THT - AS 18/18
1.4512
45 mm
1,5 mm
115
106
97
- 25,9
77
68
59
- 18,2
X 2 CrTi 12
50 mm
1,5 mm
116
103
92
- 19,45
81
73
68
- 25,63
50 mm
0,7 mm
115
108
92
- 14,5
1.4510
50 mm
1,2 mm
128
110
95
- 15,54
122
100
82
- 11,76
X 3 CrTi 17
50 mm
1,5 mm
123
106
91
- 15,08
88
79
71
- 21,97
1.4509
X 2 CrTiNb 18
50 mm
1,2 mm
130
104
84
- 10,51
124
102
84
- 12,03
1.4526
X 6 CrMoNb 17-1
50 mm
1,2 mm
160
128
102
- 10,34
119
107
96
- 21,05
115
108
101
- 35,7
99
89
79
- 20,03
50 mm
0,7 mm
1.4301
50 mm
1,2 mm
X 5 CrNi 18-10
50 mm
1,5 mm
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RENAULT
2.8.
Deformation mode
Grade
Bending R / D maxi.
(angle = 90)
1)
Tube
Tube
40 x 1,5 55 x 1,5
Price
(1 to 5)
index
Flanged
cone 60
%
ES
ESHT
CS
ES - AS 18/18
1,2
1,2
50
ES HT - AS 18/18
1,2
1,2
50
CS - AS 18/18
1,3
1,3
45
E THT - AS 18/18
1,5
1,5
45
X 2 CrTi 12 (brut)
(1.4512)
1,4
1,4
45
4 to 5 4 to 5
1,3
1,3
45
4 to 5 4 to 5
2)
(au
19/5/98
X 2 CrTi 12
(annealed)
(1.4512)
X 6 Cr 17
(1.4016)
61
3
X 3 CrTi 17
(1.4510)
4
1,3
X 6 CrMo 17-1
(1.4113)
64
87
100
45
-
4 to 5 4 to 5 4 to 5 4 to 5
116
4 to 5 4 to 5 4 to 5 4 to 5
1,3
60
X 2 CrTiNb 18
(1.4509)
119
X 6 CrMoNb 17-1
(1.4526)
1,3
1,3
45
X 5 CrNi 18-10
(1.4301)
1,1
1,1
50
151
X 6 CrNiTi 18-10
(1.4541)
1,1
1,1
50
157
4 to 5 4 to 5 4 to 5 4 to 5
144
1)
2)
Price index indicated on base 100 for tube TSR X2 CrTi 12 (1.4512) 50 x 1,5 mm, length1 500
mm (extra-alloys included).
2.9.
RESISTANCE TO CORROSION
2.9.1.
Appearance as per T C
(B.E target service life)
Grade
Brilliant
Oxidation or
alliation with
grey
appearance
Corrosion
when cold
Red rust
< 1 % of red
rust
ES - AS 18/18
< 450 C
450 C
ES HT - AS 18/18
< 450 C
800 C
6 years
without R.R.
on specimen
surface
CS - AS 18/18
< 450 C
450 C
(of 30 Lardy
cycles)
after 9 cycles
of test
E THT - AS 18/18
< 450 C
900 C
RENAULT 2001
To be indicated by SOLLAC
of corrosion
3C 1)
Page 20/42
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2.9.2.
Stainless steels
Appearance as per T C
(B.E target service life)
Brilliant
Oxidation or
alliation with
grey
appearance
Corrosion
when cold
Red rust
Isothermal oxidation
2)
Cyclic oxidation at
950 C
3)
800 C
850 C
900 C
100 h
400 h
X 2 CrTi 12 (brut)
(1.4512)
Delivered mat
20
200
outside
range
outside
range
X 2 CrTi 12
(annealed)
(1.4512)
Delivered mat
20
200
outside
range
outside
range
5,5
15
32
2,5
3,25
15
X 6 Cr 17
(1.4016)
Colouring
X 3 CrTi 17
(1.4510)
as
6 years
without R.R.
Delivered mat
of
(or 30 Lardy
cycles)
X 6 CrMoNb 17-1
(1.4526)
Annealed
brilliant
200 C
X 5 CrNi 18-10
(1.4301)
j 200 C
underway
> 200
outside
range
X 6 CrNiTi 18-10
(1.4541)
j 200 C
underway
180
>> 350
X 2 CrTiNb 18
(1.4509)
none
X 6 CrMo 17-1
(1.4113)
1)
On flat specimen having being subjected to an equi-biaxial deformation of 20 % (as per 3.1.6.
of Product Specifications 11-04-809).
2)
3)
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Annex A
Correlation between mild steel grades
RENAULT
designation
of grade
RENAULT
specifications
(P) = Rolled products
(T) = Tubes
Approximate
correspondence
as per European Standard
EN 10154
SOLLAC
GALVALANGE
E.C.I.A
ES - AS 18/18
11 - 04 - 809 (P)
11 - 05 - 217 (T)
DX53D + AS 120
Alusi BSR
AL5
AS 120-05
ES HT - AS 18/18
11 - 04 - 809 (P)
11 - 05 - 217 (T)
DX55D + AS 120
Alusi BHT
ALT
AS 120-06
CS - AS 18/18
11 - 04 - 809 (P)
11 - 05 - 217 (T)
none
Alusi BV
AS 120-07
E THT - AS 18/18
11 - 04 - 809 (P)
11 - 05 - 217 (T)
none
EXTRATHERM A
AS 120-11
Commercial names
Annex B
Correlation between stainless steel grades
Designation of grade
As per EN 10088-1
RENAULT
as per previous
AFNOR
Type
A.I.S.I
Commercial names
specification
UGINE
A.S.T.
THYSSEN
* (P)
11 - 05 - 228 (T)
F 12 T
409
4512
430
none (*)
F 17
Z 4 CT 17
430 TI
or 439
* (P)
11 - 05 - 228 (T)
F 17 T
439M
1.4509
Z 3 CTNb 18
441
* (P)
11 - 05 - 228 (T)
F 17 TNb
441
X 6 CrMo 17-1
1.4113
Z 8 CD 17-01
434
none(*)
F 17 M
X 6 CrMoNb 17-1
1.4526
Z 8 CDNb 17-01
436
* (P)
11 - 05 - 228 (T)
F 17 MNb
436
4526
X 5 CrNi 18-10
1.4301
Z 6 CN 18-09
304
* (P)
11 - 05 - 228 (T)
18 - 9 E
304
4301
X 6 CrNiTi 18-10
1.4541
Z 6 CNT 18-10
321
none(*)
18-10 T
321
4541
Name
X 2 CrTi 12
1.4512
Z 3 CT 12
409
X 6 Cr 17
1.4016
Z 8 C 17
X 3 CrTi 17
1.4510
X 2 CrTiNb 18
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3.
REMINDER
Various methods are proposed to evaluate the structure of the molten metal after return to ambient
temperature according to its chemical composition:
3.1.1.
Schaeffler diagram
Schaeffler diagram
0%
Ni Equivalent
30
28
26
24
22
10 %
Zone A :
Austenite
20 %
20
Zones B and C : A + F 40 %
Zone D :
A+M
18
16
14
12
10
8
6
80 %
100 %
Zone E : Martensite
4
2
0
5%
Zone G : Ferrite
Zone F : M + F
M+F
12
16
20
24
Cr Equivalent
28
32
36
40
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Calculating the dilution rate
Lug
s1
Tube
Dilution % =
s2
s1 + s2
x 100
S
The method of utilization of this diagram may be illustrated using the following examples:
-
welding of two parts made from same steel without filler product: the figurative point of the
joint shall be that determined on the basis of the basic metal composition,
welding of two parts made from different steels without filler product: the figurative point of
the joint shall be located on the right hand segment defined by the two points determined on the
basis of the compositions of the base metals, the composition of the point will depend on the
relative contribution of each metal to the composition of the molten metal,
welding of two parts made from the same steel with a filler product: the figurative point of
the joint will shall be located on the right hand segment defined by two points determined on the
basis of the base metal composition and filler metal composition; the position of the point will
depend on the dilution,
welding by one operation on two different steel parts with a filler product: the figurative
point is determined in two stages:
1.
determine relative mean point relative to base metals (by applying the procedure described
for welding various steels without filler metal),
2.
determine figurative point of molten metal (by applying the procedure described for welding
two identical steels with filler metal on the basis of the mean point of base metals and the
relative point of filler metal by incorporating dilution).
All these points fall within the various zones of the diagram, which provides a view of the joint of base
metal and of the risks associated with welding.
-
Zone A ( austenite):sensitivity to cracking when hot, good resistance to corrosion and heat.
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-
Zone E ( martensite ) : cracking at temperature < 400 C imperative preheating before welding.
3.2.
3.2.1.
During thermal welding cycles, these steels do not sustain any structural transformation and
accordingly the main result of the heating of the metal to a high temperature will be a significant grain
expansion.
It is important to note that the brittleness after welding of the steels that do not contain a stabilizing
additive element (Ti or Nb) is more a result of the presence of martensite at the joints that of grain
expansion; unless such grains have reached significant dimensions, e.g. 3 mm. Steels containing an
addition of Ti or Nb, owing to the presence of TI or Nb precipitates, are slightly less sensitive to this
condition. This also applies to steels with a very low content of carbon and nitrogen.
In short, the sensitivity of these steels to the thermal effects of hot working and welding may have
four origins:
-
expansion of grains that cannot be refined except by significant work hardening when cold
followed by heat treatment, which would prompt recrystallization,
precipitation, during rapid cooling, of a martensitic phase consisting of a surface film on the grain
joints,
precipitation prompting structural hardening and affecting all chromium steels containing more
than 13 to 14 % of chromium. The temperature hold time necessary to conduct precipitation is
shorter as the chromium content increases. The temperature zone liable to cause precipitation is
between 350 and 550 C. It should be noted that this phenomenon is reversible and it is
possible to recover these precipitations, and thereby eliminate this brittleness, by heat treatment
at 800 C,
In addition, heating of the metal in the ZAT above 950 C, causes the chromium carbides to dissolve.
These will reprecipitate during cooling. Such intergranular precipitation of the chromium carbides
causes intergranular sensitivity to corrosion unless the carbon content of the steel is very low or if the
steel contains a sufficient quantity of Ti or Nb.
3.2.2.
3.2.2.1.
Because of grain expansion and the presence of martensite, resilience at ambient temperature is
generally low. The assembly becomes sensitive to brittle rupture, however for this to occur, the metal
will have to be subjected to tri-axial stress (which excludes constructions made from thin products
from this risk) and to rather brutal loading conditions. Accordingly, we are only interested here in the
welding of products that do not exceed 6 mm.
Furthermore, and more for other stainless steels, welding procedures by fusion that may be employed
when processing ferritic stainless steels shall ensure perfect protection against molten metal. This
requirement significantly reduces the possibilities of welding with a coated electrode, which does not
ensure perfectly satisfactory protection.
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Accordingly, procedures used for welding ferritic stainless steels will preferably be those using
protective gas flow, i.e. TIG, MIG and plasma welding.
For these procedures, the following requirements shall be ensured:
-
good continuity without any surface defects that may constitute incipient corrosion,
a good conservation of resistance to corrosion of the assembly. This result will be obtained if the
procedure prevents the departure of useful alloy elements (in particular, chromium) and the
addition of any noxious element such as carbon (which would create the risk of porosity
formation),
good mechanical strength which is usually achieved if the geometry of the assembly and the
molten metal are satisfactory, in particular with respect to the latter, if the problems caused the
presence, if any, of martensite and intergranular chromium carbides have been resolved.
limit the quantity of energy applied (< 7 KJ/cm) during welding in order to reduce, insofar as
possible, grain expansion,
during welding of totally ferritic steels, avoid any addition of carbon and nitrogen liable to cause
the formation of martensite and thereby reduce the ductility of the molten metal,
choose welding products that do not add hydrogen (pure argon, if necessary basic
electrodes appropriately cured),
carefully prepare the parts to be assembled (elimination of lubricant traces, rust, humidity,
dirt),
For molten metal, high ductility may confer it with an austeno-ferritic structure by using an austenitic
filler metal. It should be noted however that this procedure does not resolve the metallurgical
problems caused by the zone affected by the heat and that furthermore no post-welding treatment
should be performed as there is a risk of thermal treatment on the austenitic steel.
3.2.2.2.
TIG welding
In this procedure, the protection of the molten metal and of the hot metal is ensured by neutral gas.
It may consist of:
-
pure argon,
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The filler metals used for welding the ferritic stainless steels are not defined in a specific standard.
In general, a filler metal with a similar composition (use of Schaeffler diagram) as that of the base
metal is chosen. For the welding of totally ferritic steels, the filler metals containing titanium or
niobium, have a higher chromium content and a lower carbon content in order to avert the risk of
martensite appearing in the molten metal.
3.2.2.3.
MIG welding
This procedure uses a fusible electrode in the form of a renewable wire, the protection of the molten
metal and of the hot metal being ensured by a current of inert gas.
The filler wire contains the filler elements necessary to form the molten metal.
The protection gas may consist of:
-
pure argon or argon to which small quantities of other gases (CO2 or O2) have been added. The
addition of the gas increases the stability of the arc, improves wetting of the base metal and
increases penetration; however, it creates a risk of metal impoverishment in terms of oxidable
alloy elements (Cr and Ti),
The useable filler metals for MIG welding may be of the same type as those employed during TIG
welding however their content in silicon shall be slightly higher (up to 1,1 %) in order to improve the
deoxidation of the of the bath and wetting of the base metal; however, more generally, they are made
from austenitic steel.
3.2.2.4.
This procedure uses electrodes whose metallic core has a chemical composition which generally
corresponds to that of the metal to be welded.
The function of the coating is to ensure the protection of the molten metal by the diffusion of carbonic
gas (due to the dissociation of carbonates incorporated in the coating) and the formation of a
protective slag. In certain cases, the necessary alloy elements may be added by this coating in rather
large proportions.
In general, it is considered that with the shielded metal arc welding of ferritic stainless steels, the
protection obtained is not totally satisfactory and there is a tendency not to recommend this process.
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3.3.
3.3.1.
In general, the chemical composition of these steels is established such that, upon equilibrium, their
structure is austenitic at all temperatures of less than 1 100 C approx. At higher temperatures, the
structure may be either mixed austeno-ferritic, or even totally ferritic.
It should be noted here that the presence of carbon in austenitic stainless steels may be responsible
for the deterioration in their resistance to corrosion when such steels are subjected to a long duration
at temperatures of between 500 and 850 C. In effect, if the conditions permit (slow cooling, hold at
appropriate temperature), the carbon will precipitate in the form of carbides, generally chromium
carbides; this precipitation, which occurs primarily in the grain joints and elsewhere in the grains
themselves, impoverishes the chromium content of the neighbouring austentite, thereby rendering it
sensitive to corrosion in an intergranular fashion.
However, as already seen, there are two types of procedures to reduce or eliminate the risk of
precipitation:
-
An austenitic steel weld may sustain cracking at high temperature (hot cracking) caused by shrinkage
that develops in the interdendritic spaces of the molten metal. The presence of certain elements
facilitates such cracking: sulphur, silicon, niobium, phosphorous, boron. The most efficient remedy,
apart from adding manganese, consists in ensuring that the metal contains a certain proportion of
ferrite (from 1 to 5 %). It is also recommended to weld while limiting the energy intake and check that
between the passes, the temperature of the joint drops sufficiently (< 100 C).
Furthermore, there is a risk of a sigma phase occurring in austenitic steels (see 3.3.2.).
3.3.2.
Sigma phase
Intermetallic compounds may be formed at high temperature in stainless steels, beyond a chromium
level of 18 to 20 %, and in the welds. These compounds may enclose notable quantities of other
elements than iron and chromium. Their occurrence in a large quantity has the effect of reducing the
ductility of the alloy, a very significant reduction in elongation, a reduction the resilience of the steel,
with an increase in hardness and sensitivity to incision. In addition, under certain conditions, the
resistance to corrosion of the steel is greatly affected by the sigma phase.
Conditions of formation:
-
Temperatures: Hold the alloy between 550 and 900 C; beyond 900 C, stability limit and
possibility of return to solution.
Extremely low formation between 550 and 600 C
Very rapid formation in the region of 800 - 850 C.
Nickel and carbon reduce the tendency of steels to form the sigma phase.
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3.3.3.
3.3.3.1.
A number of fusion welding processes may be used in order to attach stainless steels. In this paper,
we focus on the most commonly used.
For these processes, ensure:
-
good geometrical surface continuity without any defects that may constitute incipient corrosion,
satisfactory preservation of resistance to corrosion of the assembly. This result will be obtained if
it prevents the separation of useful alloy elements (in particular, chromium) and the addition of
noxious elements such as carbon,
good mechanical strength, which will generally be achieved if the geometry of the assembly and
the chemical composition of the molten metal are satisfactory, especially if the conditions
necessary to prevent cracking under heat are satisfied.
3.3.3.2.
The purpose of these modifications are to counteract any metal deficiency in Cr and Mn and any
enrichment in C so as to contribute to the attainment of good corrosion resistance. Furthermore, such
differences enable the acquisition of the quantity of ferrite necessary to eliminate the risk of cracking
when hot.
It should be noted that amongst the chemical compositions of the deposited metals, there is no
titanium metal; this condition is due to the fact that titanium oxidizes and its transfer is not optimum in
the electrical arc. For welding titanium steels, it is therefore necessary to use electrodes depositing a
metal containing niobium.
3.3.3.3.
TIG welding
MIG welding
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3.4.
3.4.1.
General
This type of assembly remains a special case that can only be processed by a specialist after
examining all the specific aspects. In this document, therefore, we will only devote a brief overview to
this procedure.
When a non alloyed carbon steel or a ferritic steel is assembled with an austenitic steel, the filler
metal is chosen according to the Schaeffler diagram (see 3.1.1.). The objective is to obtain a
molten area with a austeno-ferritic two-phase structure. In effect, a content greater than 2 % of ferrite
is desirable in order to avoid the hot cracking phenomenon.
To ensure weldability in the molten zone, it is essential to avoid the "high risk" structures:
-
risk of brittleness during sigma phase if the chromium equivalent placed on the Schaeffler
diagram is very high.
In practice, the structure without any metallurgical problem is situated around an eqCr = 20 and an
eqNi = 11 in the Schaeffler diagram. This is confirmed on the various Bystram diagrams, which
identify the various high risk zones and the optimum weldability zone on the Schaeffler diagram.
3.4.2.
3.4.2.1.
Bystram diagrams
Cold cracking area
0%
30
5%
10%
28
26
Austenite
24
20%
22
20
Niq
A+F
18
40%
A+M
16
80%
14
12
10
100%
8
Martensite
6
4
2
Ferrite
M+F
M+F
0
0
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12
16
20
Crq
24
28
32
36
40
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3.4.2.2.
30
5%
10%
28
26
Austenite
24
20%
22
20
A+F
18
40%
A+M
16
Niq
80%
14
12
10
100%
8
Martensite
6
4
Ferrite
M+F
2
M+F
0
0
3.4.2.3.
12
16
20
Crq
Grain expansion brittleness area
24
28
32
36
0%
30
40
5%
10%
28
26
Austenite
24
20%
22
20
A+F
18
40%
A+M
16
80%
14
12
10
100%
8
Martensite
6
4
Ferrite
M+F
2
M+F
0
0
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12
16
20
24
28
32
36
40
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3.4.2.4.
30
5%
10%
28
26
Austenite
24
20%
22
20
A+F
18
40%
A+M
16
Niq
80%
14
12
10
100%
8
Martensite
6
4
Ferrite
M+F
2
M+F
0
0
3.4.2.5.
12
16
20
Crq
24
28
32
36
40
30
5%
10%
28
26
Austenite
24
20%
22
20
A+F
18
40%
A+M
16
Niq
80%
14
12
10
100%
8
Martensite
6
4
Ferrite
M+F
2
M+F
0
0
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12
16
20
Crq
24
28
32
36
40
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4.
MIG WELDING
4.1.1.
Description of process
Definition: The MIG/MAG welding process applies an arc under gas protection. The electrode is
fusible and serves as a filler metal. The electrode, the metal transferred in the arc and the liquid weld
metal are protected from ambient air by a gas flux, which is inert in the case of MIG welding and
active in the case of MAG welding.
Hence the terms MIG Metal Inert Gas and MAG Metal Active Gas. During Manuel welding, these
processes are also called "semi-automatic" because the wire is unrolled automatically as soon as
arcing commences. The MAG process, in an active atmosphere, is reserved for steels with a low or
without any alloy content. The MIG process, in an inert atmosphere, is used for light alloys and
cupreous alloys. In the case of stainless steels, when the atmosphere is slightly active, the term MIG
is usually used to differentiate from the case of carbon steels.
Gun
Fusible
electrode
wire
Mtal
transfr
Gas shield
Deposited metal
Base metal
Electrical supply: The MIG/MAG welding arc is supplied with a direct current in reverse polarity with
the fusible electrode at the positive pole. The wire is then subjected to an electron flux, which
facilitates its fusion. Reverse polarity ensures better arc stability.
Direct polarity is not suitable because it causes less heating of the wire, the metal drops are bigger,
fewer in number and they do not detach in a very clear manner. The seam obtained is dome shaped.
In exceptional cases, e.g. on sheathed wires, this polarity is not employed.
_
e
+
+
e
_
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Field of application: Productivity is the main advantage of the MIG and MAG welding processes.
Because the volume of metal deposited is very large, these processes are suitable for big thicknesses
and for filling the chamfer by multiple runs. Easily implemented, the MIG and MAG welding processes
can be applied manually, automatically or robotically. They enable welding in all positions.
4.1.2.
Metal transfer modes inj the arc. (Pulsed, Lincoln STT, axial spray)
The fusion of the wire and the transfer of metal in the arc may be conducted in many ways depending
on the type of protective gas, voltage and current of the arc.
4.1.2.1.
Time
A
150
100
50
Arc time
Short-circuit
time
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Globular transfer:
At welding energies between those providing short-circuit transfer and axial spray transfer, the drops
build up slowly. The current amperage is not high enough to create a pinching effect inducing
separation and the drop gets bigger exceeding the size of the wire diameter. Transfer occurs by shortcircuit when the drop touches the liquid metal, or by separation of the drop under the effect of gravity.
The drop then follows a random path, which is not always aligned with the axis of the arc. This is an
unstable transfer mode inducing weak penetrations and numerous splashes. If possible, it should be
avoided.
4.1.2.2.
Pulsed setting:
Current peaks are superimposed onto a basic current which maintains the established arc. When the
pulse is applied, the high current density causes a fine droplet to be transferred. This transfer is
comparable to axial spray (stability, absence of splash) however the average current is lower. If the
thickness or the welding metallurgy requires an energy corresponding to a conventional globular
transfer, the use of a pulsed current eliminates the problems associated with globular transfer.
Current
Peak current
Average current
Basic current
Time
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Controlled short-circuit transfer (Lincoln STT).
This process has been designed to avail of the advantages of the short circuit transfer process while
avoiding the disadvantages (bonding, splash reduction, arc instability, etc.). To do so, the current is
reduced by about 10 A when the wire comes into contact with the part in order to avoid splashing.
After this period, a higher current is applied in order to accelerate the pinching effect and thereby
reduce the cold period causing arc instability. The current level is then reduced a few millionths of a
second before separation of the drop to a value sufficiently low to ensure there are little or no
splashes. A very high current is then applied (in the order of 300 to 450 A) after the drop has
separated in order to avoid any risk of bonding.
4.1.3.
Gas protects the liquid weld metal and the metal transferred in the arc from the ambient air. The gas
should also facilitate the formation and stability of the arc.
Inert gas:
Argon, owing to its characteristics, is the basic gas used for MIG welding. Helium can also be added.
The greater the arc voltage, the hotter and more diffuse the arc, a condition that increases the
penetration or welding speed, improves wetting and makes for a flatter seam. Argon and mixtures of
argon and helium are used for aluminium and copper alloys.
Carbon dioxide:
MAG welding of steels is different from MIG welding in that it is conducted in an oxidizing
atmosphere. Originally, the gas used was carbon dioxide. The dissociation of CO2 in the arc leads to
the formation of oxygen, which causes localized oxidation. Such oxides are emitted, the arc remains
attached and stable. However the CO2 atmosphere causes significant oxidation of the metal and the
loss of alloy elements (except carbon). The type of wire used is therefore very important in order to
limit this phenomenon.
Under the current range conventionally used, the CO2 does not enable transfer by axial spraying.
The pinching effect is minimal, the significant viscosity of the molten wire causes bit drops which are
transferred in an explosive manner inducing instabilities and splashes. Pure CO2 is therefore limited
to short circuit and big drop transfers, whereby the viscous liquid enables work in all positions. The
disadvantages of CO2 are eliminated by argon-CO2 mixtures, which enable transfer by axial spraying.
Standard mixtures have a CO2 content of between 2 and 25 %. Small additions are used for stainless
steels, the bigger contents for carbon steels. In the case of stainless steels, an excessive percentage
of CO 2 may cause carburation liable to undermine the corrosion resistance.
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In the case of carbon steels, mixtures with a CO2 content less than 10 % improve surface appearance
and limit the formation of silicates. The amount of splash and fume emissions are also reduced. A
gas limiting the amount of splash can be used to considerably reduce the soiling of the welding gun.
Oxygen:
Oxygen may be used instead of CO2 in order to stabilize the arc. By reducing the surface tension of
the liquid metal, oxygen facilitates the formation of drops and improves wetting of the bath. By
making a more rigid and hotter arc than the one formed with CO2 , the addition of oxygen facilitates
the transfer by axial spraying and subsequently induces more effective penetration than with argon
-CO2 mixtures. Oxygen argon mixtures contain between 1 to 8 % of oxygen, smaller contents are
used for stainless steels. Ternary mixtures may be used (Ar - CO2 - O2).
Hydrogen:
When welding stainless steels, low hydrogen contents (< 3 %) may be added. Like helium, hydrogen
increases the energy of the arc by applying a higher voltage level. Because of its reducing power, the
hydrogen provides a very clean seam appearance. Hydrogen may be the cause of cold cracking of
quenched materials. Mixtures containing hydrogen are therefore mainly used for austenitic steels.
Hydrogen may cause porosities in the weld seams. Mixtures containing hydrogen shall be mainly
used for one-run welding.
GAS
Advantages
Disadvantages
Ar
Inert
He
Inert
"Hot" gas
increased V welding
Limited to 20 %
vertical and ceiling
CO2
Oxidizing
(< O2)
Limited to 20 %
practical < 5 %
Prohibited for TIG
O2
Oxidizing
Highly oxidizing
oxidized seams
Prohibited for TIG
H2
Reducing
"Hot" gas
increased V welding
Reducing
Blank seam
N2
Neutral
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4.1.4.
Electrodes used for manual electrical arc welding with a fusible electrode wire in the form of a
continuous thread reaching the arc at which point it melts. The wires used are solid bare wires, or
bare flux-cored wires. The first make the use of a protective gas mandatory, the second may be used
with or without a protective gas, in which case the liquid metal is shielded either by the action of the
core flux (formation of a slag and a gas) or by the combination of the action of the flux and that of the
protective gas.
Composition:
By its very composition, the wire incorporates the elements liable to modify the characteristics of the
weld. The alloy elements shall be adjusted in order to obtain a weld, the properties of which are equal
to or better than those of the base metal (mechanical properties, corrosion...).
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SCHAEFFLER DIAGRAM
24
20
16
9
0
%
5
Austnite
e
rit
er
F
%
10
8
%
20
3
2
12
%
40
A+F
%
80
1
8
100 %
A+M+F
4
M+F
0
Ferrite
F+ M
0
12
16
20
24
28
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36
40
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However, low additions of certain elements may have consequences on:
-
the stabilization of the arc and on the transfer of the metal due to active components,
the reduction of splashes and fumes (elements such as titanium, silicon, manganese facilitate
such a reduction),
the reduction of oxygen in the welded metal: the use of oxidizing gases is compensated by the
addition of deoxidizing elements in the wire such as manganese and silicon. The silicates thus
formed are deposited on the upper part of the weld.
The elements contained in the core may be either metallic or non-metallic, the functions of these
elements are:
-
act as a deoxidant,
There are two main families of flux-cored wires: those used without protective gas and those used
with protective gas.
During welding with a flux-cored wire without gas protection, the core protects the molten metal by
diffusing gases into the arc and by producing a slag that covers the molten metal. The use of such
wires is advantageous on a job or at any location where it is difficult to bring in gas. However, they
are difficult to use meaning that the welders require good training.
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More commonplace, the flux-cored wires with gas may be divided into two families:
-
1 - Rutile flux-cored wires (transfer in fine droplets and average level of hydrogen, welding in all
positions),
2 - Basic flux-cored wires (globular type transfer and very low level of hydrogen,
position work),
delicate
4.2.
TIG WELDING
4.2.1.
Description of process
Definition: TIG welding, inert gas welding with non fusible electrode, is a procedure in which the
energy necessary for the fusion of the parts to be assembled is provided by an electric arc
established between a refractory tungsten electrode and the joint to be welded. The electrode and the
liquid metal are protected from ambient air, i.e. from nitrogen and oxygen by an inert gas flux. Hence
the term Tungsten Inert Gas.
Depending on the job at hand, the thickness, geometry of the joint, type of materials to be assembled,
a filler metal in the form of a strip may be used. This wire is melted in the arc and protected by the
inert atmosphere of the welding gas.
Gun
Filler
metal
Inert
gas
Refractory
tungsten
electrode
Arc
Base metal
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Liquid
weld metal
Molten
area
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Electrical supply: The type of current depends on the material to be welded and on the assembly to
be formed:
-
Direct current: Direct polarity (negative pole on electrode) for welding of all metals.
Pulsed current: This technique, consisting in successively developing periods of high an low
current amperage, is used to reduce the volume of the molten metal. This facilitates the position
work, the welding of thin assemblies and ensures optimum regularity of the penetration.
Alternating current: Mainly used for the welding of aluminium alloys. Upon alternation to the
reverse polarity, the gush of electrons from the sheet towards the electrode cracks the
refractory alumina layer. At the subsequent alternation, the direct polarity ensures penetration.
Field of application: TIG welding is characterized by the high quality of welding achieved. The liquid
metal is calm, there are no splashes and only a small amount of fumes. To benefit from such ha level
of quality, it is necessary to work with special care ( Clean and stripped sheets, separated straight
edges, constant arc length, regular welding advance ).
TIG welding is used to weld most metals and alloys, whether on the flat or in position. It is conducted
manually, automatically or robotically.
The weldable edge-to-edge thicknesses for a single-pass weld with argon, are between 0,5 mm and
3 mm for most materials. It is also possible to weld thicknesses greater than 3 mm, by preparing the
edges to be assembled (chamfer) and by multiple-pass welding. However, because the welding speed
and the volume of metal deposited are low, TIG welding is preferably used to ensure a regular
penetration and satisfactory quality at the first pass.
5.
BIBLIOGRAPHY
Soudage a larc Tome 3 by Bertrand le Bourgeois, Publication de la soudure Autogne.
Les aciers inoxydables , Mise en uvre et soudage by J. Varriot.
Prcis de mtallurgie by J. Barralis and Grard Maeder.
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