The Effects of Phosphorus, Sulfur
and Ferrite Content on W e l d Cracking
of Type 309 Stainless Steel
The ferrite level that prevents cracking is found to be
on impurity level wherein, for low P + S, little or no ferrite is required
to prevent cracking while, with ferrite contents greater than
Ferrite Numbers 13 to 14, large amounts of P and S
can be accommodated
By J. A. BROOKS A N D F. J. LAMBERT, JR.
ABSTRACT. The variation in weld
cracking of different heats of Type 309
stainless steel is reviewed. Data are
presented which show the combined
effects of phosphorus plus sulfur
level and ferrite content on weld
cracking. The data demonstrate that
chemistry specifications more restric-
tive than the current AISI specification
are required to ensure crack-free auto-
geneous welds.
Introduction
As pointed out by Lundin et al.,1 the
construction of nuclear power reactors
using large amounts of austenitic
stainless steels has renewed interest in
the subject of ferrite and weld micro-
fissuring. The potent effect of several
percent ferrite in reducing cracking
has been k n o w n for years2 and
resulted in the development of a
number of diagrams, such as that
published by Schaeffler,3 and later
revised by DeLong et al.,4 w h i c h
predicts weld ferrite content from
chemical composition.
The relationship between ferrite
content and weld cracking has led to
the development of codes w h i c h
require weld ferrite above a specified
minimum level in an attempt to elimi-
nate cracking. However, in some cases
designers w o u l d like to minimize, or
eliminate, ferrite for reasons such as
preventing transformation of delta
ferrite to sigma phase, or excluding
magnetic phases, for example, in
constructing hardware for super con-
dependent
without cracking
ductivity. Therefore, conflicts often
arise between the designer and w e l d -
ing engineer.
Lundin and co-workers 1 determined
the minimum ferrite content required
to eliminate weld fissuring of several
AISI 300 series alloy wire filler metals
and thoroughly characterized the m i -
crofissures of "fissure b e n d " test
samples. In their study they did not
consider the effect of impurity ele-
ments which can alter the relationship
between ferrite content and cracking.
This relation was, however, clearly
shown by one of the present authors
for high nitrogen, high manganese
stainless steels.5 In both weld wire
filler metals and wrought material,
phosphorus and sulfur levels in par-
ticular can vary considerably, and have
a significant effect on weld cracking.
Impurity levels in wrought material
cannot be ignored, since cracking can
Paper based on information included in
presentation made under title of "Effects of
Impurities on the Weldability of Electro-
formed Nickel" in a session sponsored by
the Wrought Nickel Alloys Subcommittee
of the Welding Research Council at the
AWS 57th Annual Meeting held in St. Louis,
Missouri, during May 10-14, 7976.
/. A. BROOKS is with the Materials Devel-
opment Division, Sandia Laboratories,
Livermore, California, and F. I. LAMBERT,
JR., now retired, was with the Union
Carbide Corp., Y-12 Plant, Oak Ridge,
Tennessee.
W E L D I N G RESEARCH S U P P L E M E N T I 139-s
result in autogeneous welds or the
root pass of multiple pass welds.
The purpose of this paper is to
demonstrate the importance of
(P + S) content in the relationship
between weld cracking and ferrite
content of autogenously welded AISI
309 austenitic stainless steel, one of
the alloys studied by Lundin.
Material and Testing
Studies were conducted on 42
different heats of Type 309 austenitic
stainless steel which contained various
phosphorus and sulfur levels. The
heat chemistries are shown in Table 1.
Alloys 1 to 16 were produced from 1 kg
(2.2 lb) vacuum induction melted
(VIM) heats, alloys 17 to 40 were from
1.8 kg (4 lb) V I M heats, and alloys 41
and 42 were from commercial heats.
All material was homogenized and hot
rolled to 0.25 mm (0.01 in.) thick strip.
These strips were annealed at 1010 C
(1850 F), air cooled, pickled, and
finished w i t h a light cold-roll pass.
All experimental heats were made
from high purity starting material w i t h
the main alloying elements balanced
to provide a range in ferrite content
when welded. However, it was in-
tended that all heats should be w i t h i n
the commercial AISI specification
shown in Table 2. W h e n the allowable
chemistry range of the Type 309 stain-
less steel is plotted on the DeLong
Diagram 6 (Fig. 1), it is easily seen that
autogeneous GTA welds in this alloy
could exhibit ferrite levels from ferrite
Table 1 - Chemistries of Type 309 Stainless Steel Heats Studied, Wt-%

N N Crack
Heat Cr Ni Mn Si C P S heat weld F.N.'* rating

1 21.7 15.0 1.44 .69 .075 .002 .003 .026 1 1, 1

2 21.6 14.9 1.48 .75 .077 .043 .024 .016 2 4
3 21.7 15.0 1.76 .73 .078 .041 .033 .140 0 4
4 21.7 14.8 1.54 .73 .076 .039 .022 .023 1.9 4
5 21.7 14.9 1.44 .66 .082 .018 .013 .031 1.0 3
6 22.4 14.2 1.43 .71 .072 .058 .029 .026 6 3
7 22.3 13.9 1.47 .72 .048 .040 .027 .025 9 4
8 22.7 14.3 1.58 .68 .093 .042 .023 .022 5 4
9 22.7 13.9 1.41 .79 .046 .028 .027 .022 12 3
10 23.2 14.3 1.44 .67 .067 .018 .011 .050 7 2, 3
11 22.0 13.7 1.50 .71 .062 .058 .031 .026 6.5 4
12 21.9 13.3 1.77 .54 .027 .043 .027 .032 9 1
13 22.4 13.6 1.45 .74 .100 .041 .023 .020 6 4
14 21.7 13.3 1.68 .53 .029 .031 .017 .037 7.5 3, 4
15 22.0 13.5 1.45 .65 .100 .041 .013 .029 4 4
16 22.7 13.7 1.55 .56 .026 .018 .012 .023 12 1
17 22.2 14.0 1.75 .70 .043 .010 .005 .007 .012 8 1, 1
18 22.0 14.3 1.74 .70 .043 .015 .010 6.5 1, 1
19 21.9 14.3 1.74 .72 .041 .016 .010 .010 6.5 1, 2
20 21.9 14.3 1.74 .71 .040 .021 .015 .006 6.5 2, 2
21 22.1 14.2 1.58 .71 .051 .025 .024 7.0 4, 4
22 22.1 14.3 1.58 .73 .057 .020 .032 6.5 4, 3
23 21.9 14.6 1.61 .70 .059 .036 .033 .006 .014 4.5 4, 4
24 21.9 14.2 1.60 .70 .060 .004 .039 .012 5.5 4, 4
25 24.0 14.0 1.55 .71 .054 .015 .009 15 1, 1
26 23.7 14.2 1.56 .72 .048 .015 .018 14 1, 1
27 23.6 14.3 1.52 .74 .051 .021 .018 13 1, 1
28 23.8 14.2 1.54 .73 .050 .028 .024 .016 14 1, 1
29 23.9 14.1 1.53 .72 .054 .030 .043 14.5 1, 1
30 23.5 14.3 1.60 .71 .061 .034 .045 12 3, 2
31 23.6 14.4 1.60 .71 .074 .031 .052 .006 10.5 3, 3
32 23.6 14.3 1.59 .71 .063 .037 .053 .007 .013 11.5 3, 2
33 25.1 14.1 1.58 .71 .049 .020 .015 ~20 1, 1
34 24.9 14.2 1.62 .70 .045 .021 .024 18.5 1, 1
35 25.0 14.2 1.63 .71 .067 .035 .024 .017 17 1, 1
36 24.9 14.2 1.60 .71 .050 .030 .030 .006 18 1, 1
37 25.1 14.0 1.56 .73 .049 .048 .044 -20 1, 1
38 24.8 14.3 1.60 .73 .050 .044 .053 17.5 1, 1
39 24.6 14.5 1.67 .72 .068 .058 .054 14.5 1, 1
40 24.7 14.3 1.60 .71 .061 .051 .052 .006 16.5 1, 2
41 22.6 13.7 1.56 .55 .06 .013 .007 .110 9 1, 1
42 22.6 14.36 1.50 .44 .056 .025 .025 .056 6.5 4, 4

"F.N.-Ferrite Number calculated from the DeLong Diagram using nitrogen of weld analysis, or 0.020 if not analyzed.

number* (F.N.) = 0 to F.N. > 18 de-
pending upon heat chemistry.
A weld test was established 7 to
determine the cracking sensitivity of
the 0.25 mm (0.01 in.) thick sheet.
Strips, each 100 mm w i d e by 200 mm
long, (315/6x7'/s in.) were welded end-
to-end to a standard Type 304L stain-
less steel strip of equal size. The test
was performed by making a series of
fusion passes side by side along the
length of the combined standard and
test specimen strips. The standard
Type 304L stainless steel strip was used
to help detect any sutble changes in
weld parameters or weld technique
which may effect weld bead geometry
*Ferrite content is reported in ferrite
number as preferred by the Welding
Research Councilsee "Technical Note:
Calibration Procedure for Instruments to
Measure the Delta Ferrite Content of Auste-
nitic Stainless Steel Weld Metal" by W. T.
DeLong, Welding Journal, 52 (2), Feb. 1973,
Research Suppl., pp. 69-s to 72-s.
ot test results.
The samples, secured in a seam
welding unit, were welded w i t h the
following parameters: 30 A, 8 V, 610
m m / m i n travel speed w i t h argon
shielding. Twelve to sixteen weld
passes were usually made unless the
test piece proved to be very crack
sensitive, in which case the test was
terminated early. This test was per-
formed twice on each test panel. If the
test specimen showed no visible
Table 2AISI Specification for Type
309S'"' Stainless Steel, Wt-%
c 0.080 (max)
Ni 12.00-15.00
Cr 22.00-24.00
Mn 1.0-2.0
Si 1.00 (max)
P 0.04 (max)
S 0.03 (max)
"S = low carbon grade.
cracks, the back side of the weld was
painted w i t h dye penetrant and the
top side w i t h a developer w h i c h could
easily detect the through thickness
cracks. A qualitative rating of 1-4 was
established: (1) no cracks, (2) no more
than t w o cracks, (3) more than t w o
cracks, and (4) the dye check was not
needed since it was possible to see
through cracks.
The ratings for each heat are shown
in Table 1. A completed test specimen
which proved to be very crack-sensi-
tive is shown in Fig. 2. All cracks were
centerline in nature and in some
severe cases extended the total length
of the test specimen. A section of test
plate showing the weld geometry and
spacing is shown in Fig. 3.
The weld ferrite content was calcu-
lated from the DeLong Diagram since
the specimens are much too thin for
magne gage readings. W h e n available,
the nitrogen analysis from the actual
welds were used in these calculations
since in some cases nitrogen was

140-s I M A Y 1978
 b r W i l l i a m T. D . t o n g
CONSTITUTION DIAGRAM FOR STAINLESS STEEL WELD METAL
revised January, 1973

18 19 20 21 22 23 24 25
CHROMIUM EQUIVALENT = '/.Cr + %Mo + 1.5 X "/.Si + 0.5 X */.Cb
Fig. 7DeLong Diagram showing calculated ferrite levels of welds within the Type 309 stainless steel composition range of Table 2 and 0.05%
maximum N

absorbed during welding. This can be
seen in Table 1 by comparing the heat
analysis w i t h the nitrogen analysis of
the weld metal. The effect of nitrogen
pick-up during welding has been
discussed by Long and DeLong. 8
A nitrogen level of 0.02% was used
for ferrite prediction when the weld
metal analysis was not available. As a
check between predicted and actual
ferrite content, the ferrite content was
estimated for welds of five alloys using
the line intercept technique. Scanning
electron micrographs at X3000 were
used to clearly distinguish the fine
ferrite morphology.
The measured and calculated values
are shown in Table 3. As shown, fair
agreement existed for all welds except
heat 9, which had a measured ferrite
content of 6% (F.N. 6), but a calculated
value of 10.7% (F.N.12). As discussed
later, weld test behavior of this heat
was more typical of 6 F.N. than 12
F.N.
Results and Discussion
In this study only phosphorus and
sulfur content were considered in
studying the cracking behavior even
though other elements such as silicon
and carbon can have an effect.

' 309 Ht. 42

304-309

Fig. 2Weld test sheet after dye penetrant inspection

W E L D I N G RESEARCH S U P P L E M E N T I 141-s
 Table 3Measured and Calculated Values
of Weld Ferrite Content

Ferrite
Heat Cal culated Measured,
number F.N. % %
4 1.9 1.9 1.3
5 1.0 1.0 1.6
9 12 10.7 6
11 8.8 8.2 6.5
14 10.5 9.6 7.5

The relationship found between

Fig. 3Top surface of weld test sheet showing sections of two test runs. Each test
includes 12-14 GTA weld passes
However, phosphorus and sulfur are
known to be the most detrimental
impurities c o m m o n to this type alloy,
and silicon was intentionally held
constant at a nominal range of
-0.7%.
Using "Relative Potency Factor" cal-
culations proposed by Borland 9 and
discussed by Cannonico, et al.,'" sulfur
in iron is predicted to be much more
detrimental than phosphorus in
forming low melting eutectics respon-
sible for cracking. However, from
several studies discussed by Borland
and Younger, 11 both elements seem to
exhibit approximately the same poten-
cy in producing cracking. Thus, phos-
phorus and sulfur were considered to
have equal effects on cracking and the
sum of P + S was used for comparing
the heats in this study. However, at
low levels, the detrimental effects of
sulfur are likely to be reduced by the
formation of manganese sulfide. 5
(P + S) content and ferrite number on
weld cracking is shown graphically in
Fig. 4. The data can be separated into
three regions:
1. A region where cracking is
severe.
2. A region marginal in cracking
resistance where a small amount of
cracking resulted.
3. A region where no cracking
occurred.
Figure 4 demonstrates that for very
low levels of P + S little or no ferrite
was required to prevent cracking.
However, as P + S level increased the
ferrite content also had to be
increased to resist weld cracking. At
low ferrite levels, for each 0.01%
increase in P + S content, an increase
of about 4 F.N. was required to main-
tain the same cracking resistance. At

Weld Cracking ( rating 2 , 3 - 3 - 4 . )

Q Marginally Crack Sensitive) rating 1,2-2,2)
O No Cracking! rating 1 )

' o
/ /
/ / Q
.100
/ / o
/ / o
.090
Cracking / /
1*
.080
J
/ N. /
I O
.070
/ t
on
8 / 4* 7
+ .060 : o o
7
.050 / #f
/
o
/ o
.040 i- **
o
o
.030 ' 0
.020
o
NO CRACKING

.010
o
8 10 12 14 16 18 20
Ferrite Number (F.N.)
Fig. 4Weld test results showing the relationship between (P + Sj content, F.N. and weld cracking. Ratings correspond to those
shown in Table 1. Heat 9 measured 6 F.N.-see text

142-s I MAY 1978

ferrite number greater than about
13-14, high levels of P + S were
accommodated w i t h o u t weld crack-
ing.
Heat 9 exhibited more weld cracking
than expected using Fig. 4. The line
intercept technique indicated an ac-
tual ferrite content of F.N. 6 w h i c h
would be in much better agreement
w i t h weld results than the calculated
value of 12. A likely explanation is that
in this heat more nitrogen was picked-
up during welding than indicated by
the chemical analysis which sampled
1-2 cm-. Nitrogen pick-up during
welding of 0.09% rather than the
assumed value of 0.02% w o u l d result in
the observed discrepancy in measured
and calculated ferrite levels. As shown
in Table 1, large nitrogen increases
actually did occur in several of the
welds.
The results from this study d e m o n -
strate that t w o choices are available to
ensure crack-free welds:
1. Ensure that sufficient ferrite is
produced in the weld deposit to
prevent cracking at the maximum
P + S level which can exist.
2. Or, reduce the allowable P + S
level such that less ferrite is required to
maintain the same cracking
resistance.
The latter case w o u l d be more
attractive where large amounts of
ferrite may be deterimental to other
propertiesfor example, where ferrite
may transform to sigma. In either case,
a specification w i t h different chem-
istry limits than those allowed in many
wrought alloy specifications is re-
quired to guarantee crack free welds.
This is especially true for the more
highly alloyed type of chemistry of the
AISI 300 series stainless steels.
It w o u l d be expected that the rela-
tionship between weld cracking, P + S
level, and ferrite content may be
dependent upon welding conditions
and constraint. However, the results
from this study are in good agreement
w i t h those of Lundin et a/.1 in that
both studies show that ferrite number
of about 4 is required to prevent
cracking at a P + S = 0.02 level in the
Type 309 stainless steel chemistry
range. However, this study emphasizes
the fact that the ferrite level that w i l l
prevent cracking is very dependent
upon impurity level.
Summary
The combined effects of phospho-
rus plus sulfur level and ferrite
content on weld cracking of Type 309S
stainless steel were studied. The ferrite
level that prevented cracking was
found to be very dependent upon
impurity level.
For very low levels of P + S, little or
no ferrite was required to prevent
cracking. At low levels of both ferrite
and P + S an increase of 0.01% P + S
required an increase of ~ 4 F.N. to
maintain the same cracking resistance.
However, for ferrite contents greater
than F.N. 13-14 large amounts of phos-
phorus and sulfur could be accom-
modated w i t h o u t cracking.
Acknowledgments
We wish to acknowledge the exper-
imental assistance of both D. Clark
and A. Salmi of SLL, and Billy Cross
from Oak Ridge, Y-12 plant. The
review of the manuscript by D.
Dawson and M. Mote is greatly appre-
ciated.
References
1. Lundin, C. D., DeLong, W. T., and
Spond, D. F., "Ferrite-Fissuring Relationship
in Austenitic Stainless Steel Weld Metals,"
Welding Journal, 54 (8), Aug, 1975, Research
Suppl., pp. 241-s to 246-s.
2. Borland, ). C, and Younger, R. N.,
"Some Aspects of Cracking in Welded Cr-
Ni Austenitic Steels," British Welding lour-
nal, Vol. 7, 1960, pp. 22-59.
3. Schaeffler, A. L., "Constitution Dia-
grams for Stainless Steel Weld Metals,"
Metal Progress, 56, Nov. 1949, pp. 680 and
680-b.
4. DeLong, W. T., Ostrom, G. A., and
Szumachowski, E. R., "Measurement and
Calculation of Ferrite in Stainless-Steel
Weld Metal," Welding Journal, 35 (11),
Nov. 1956, Research Suppl., pp. 526-s to
533-s.
5. Brooks, |. A., "Weldability of High N,
High Mn Austenitic Stainless Steel," We/d-
ing lournal, 54 (6), lune 1975, Research
Suppl., pp. 189-s to 195-s.
6. DeLong, W. T., "Ferrite in Austenitic
Stainless Steel Weld Metal," We/d/ng your-
nal, 54 (7), July 1974, Research Suppl., pp.
273-s to 286-s.
7. Lambert, Jr., F. J., UnpublishedUnion
Carbide, Oak Ridge Y-12 Plant, Oak Ridge,
Tenn.
8. Long, G )., and DeLong, W. T., "The
Ferrite Content of Austenitic Stainless Steel
Weld Metal," Welding Journal, 52 (7), July
1973, Research Suppl., pp. 281-s to 297-s.
9. Borland, J. C, "Suggested Explanation
of Hot Cracking in Mild and Low Alloy Steel
Welds," Welding Research Abroad, Vol.
VIM, No. 2 (Feb. 1962), pp. 73-87.
10. Canonico, D. A., Savage, W. F., Wern-
er, W. )., and Goodwin, G. M., "Effects of
Minor Elements on Weldability of Incoloy
800," Effects of Minor Elements on the
Weldability of High-Nickel Alloys, Welding
Research Council Symposium, 1969. pp. 68-
92.
11. Borland, |. C, and Younger, R. N.,
"Some Aspects of Cracking in Welded Cr-
Ni Austenitic Steels," British Welding Jour-
nal, Vol. 7, 1960, pp. 22-59.

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This publication, dated October 1977, was sponsored jointly by the Metal Properties Council, Inc. and the
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