BRITISH STANDARD BS 7475:1991

Incorporating
Amendment No. 1

Specification for

Fusion welding of
austenitic stainless
steels
BS 7475:1991

Committees responsible for this

British Standard

The preparation of this British Standard was entrusted by the Welding

Standards Policy Committee (WEE/-) to Technical Committee WEE/45, upon
which the following bodies were represented:

Associated Offices Technical Committee

British Nuclear Fuels Ltd.
British Railways Board
British Steel Industry
Stainless Steel Fabricators’ Association of Great Britain
United Kingdom Atomic Energy Authority
Welding Institute
Welding Manufacturers’ Association (BEAMA Ltd.)

This British Standard, having

been prepared under the
direction of the Welding
Standards Policy Committee,
was published under the
authority of the Standards
Board and comes into effect on Amendments issued since publication
29 November 1991
Amd. No. Date Comments
© BSI 02-1999

7642 April 1993 Indicated by a sideline in the margin

The following BSI references
relate to the work on this
standard:
Committee reference WEE/45
Draft for comment 90/75780 DC

ISBN 0 580 19972 X

 BS 7475:1991

Contents

Page
Committees responsible Inside front cover
Foreword ii
1 Scope 1
2 Definitions 1
3 Information and requirements to be agreed and
to be documented 1
4 Storage, handling and workshop requirements 1
5 Parent metal 2
6 Welding process 2
7 Welding consumables 2
8 Equipment 2
9 Butt weld details 3
10 Fillet weld details 4
11 Preparation of fusion faces 5
12 Assembly for welding 6
13 Alignment of butt joints 6
14 Fit-up of parts joined by fillet welds 6
15 Tack welds 6
16 Temporary attachments 7
17 Stray arcing 7
18 Inter-run cleaning 7

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19 Details of welding procedure
20 Approval and testing of welding procedures
21 Approval and testing of welders
22 Identification of welds
7
7
7
7
23 Inspection and testing 7
24 Quality of welds 7
25 Correction of faulty welds 8
26 Heat treatment 8
27 Weld finishing 8
Appendix A Metallurgical aspects 9
Appendix B Recommended consumables for gas
shielded arc welding and manual metal arc welding of
austenitic stainless steels 10
Figure 1 — Fillet welds applied to the edge of a part 5
Table 1 — Guidance for shielding gas selection 3
Table 2 — Recommended diameters and welding
currents for TIG electrodes 3
Table 3 — Recommended weld preparation
tolerances for butt joints 5
Table 4 — Alignment of butt joints for plates and sheets 6
Table 5 — Alignment of butt joints for pipes and tubes 6
Table 6 — Recommended consumables for gas
shielded arc welding and manual metal arc welding of
austenitic stainless steels 10
Publication(s) referred to Inside back cover

© BSI 02-1999 i
BS 7475:1991

Foreword

This British Standard has been prepared under the direction of the Welding
Standards Policy Committee.
It supersedes BS 3019-2:1960 which is withdrawn.
This standard expands and updates the recommendations given in
BS 3019-2:1960 and presents them in the form of a specification. The standard is
primarily intended for arc welding but it may be applied to other forms of welding,
e.g. laser welding.
The austenitic stainless steels covered by this specification generally contain in
excess of 16 % chromium, together with more than 8 % nickel or nickel plus
manganese. Steels within this category may also contain additional alloying
elements, such as molybdenum, titanium, niobium, carbon or nitrogen to provide
particular properties. The combination of alloying additions in all of these steels
is sufficient to give an almost entirely face centred cubic, “austenitic”, crystal
structure. However, a small amount of the magnetic ferrite phase may be present
in some steels and further small amounts of ferrite may form during autogenous
welding.
It is assumed in the drafting of this British Standard that the execution of its
provisions is entrusted to appropriately qualified and experienced personnel.
A British Standard does not purport to include all the necessary provisions of a
contract. Users of British Standards are responsible for their correct application.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.

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Summary of pages
This document comprises a front cover, an inside front cover, pages i and ii,
pages 1 to 10, an inside back cover and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on
the inside front cover.

ii © BSI 02-1999

1 Scope
This British Standard specifies requirements for the
manual, semi-automatic, automatic and
mechanized arc welding of austenitic stainless steel
in all product forms including hollow sections.
In addition to the definitive requirements, this
standard requires additional information and the
requirements of the supplier and the purchaser to
be documented.
For compliance with this standard, both the
definitive requirements and the documented items
detailed in clause 3 have to be satisfied.
Some details of metallurgical aspects are given in
Appendix A.
Typical austenitic stainless steels covered by this
specification are listed in Appendix B together with
recommended filler wires and welding electrodes.
NOTE 1 This standard is primarily intended for arc welding
but may be applied to other methods of welding, e.g. laser
welding.
NOTE 2 The titles of the publications referred to in this
standard are listed on the inside back cover.
2 Definitions
For the purpose of this British Standard, the
definitions given in BS 499-1 apply.
3 Information and requirements to be
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agreed and to be documented
3.1 Information to be supplied by the
purchaser
The following information to be supplied by the
purchaser shall be fully documented. The definitive
requirements specified throughout the standard
and these documented items shall be satisfied
before a claim of compliance with the standard can
be made and verified:
a) the application standard to be used together
with any supplementary requirements;
b) specific requirements for materials;
c) weld quality requirements including details of
surface finish and cleanliness;
d) the degree of oxidation tolerable on root beads
or the maximum oxygen content in the purge gas;
e) whether welds are to be identified to the
individual welder performing the joint.
3.2 Requirements to be agreed
The following items to be agreed between the
contracting parties, which are specified in the
clauses referred to, shall be fully documented.
© BSI 02-1999
BS 7475:1991
Both the definitive requirements specified
throughout the standard and the following
documented items shall be satisfied before a claim of
compliance with the standard can be made and
verified:
a) where no application standard exists, the weld
profile (see 9.3.1);
b) whether the use of reactive backing strips is
acceptable [see 9.4 c)];
c) when it is not appropriate to use part of the
structure as backing material, the material to be
used (see 9.5.2);
d) methods for edge preparation for welding
(see 11.2);
e) alternative technique for inter-run cleaning
(see clause 18);
f) whether written welding procedures are not
required (see clause 20);
g) the need for welding procedure tests
(see clause 20);
h) if no application standard exists, the method
and extent of inspection (see 23.2);
i) if no application standard exists, acceptance
requirements (see 24.2);
j) if more than three attempts can be made to
repair a weld (see clause 25);
k) if no application standard exists, the heat
treatment requirements (see clause 26).
4 Storage, handling and workshop
requirements
4.1 General
When storing, handling or fabricating austenitic
stainless steel, the environment shall be controlled
to avoid permanent breakdown of the surface oxide
layer, known as the passive film, which gives
austenitic stainless steel its good corrosion
resistance. Stainless steel used for manufacture or
fabrication shall be protected from contamination
during all stages of storage and work.
4.2 Contact materials
When using paints, dyes, tapes, glues, etc. care shall
be taken that the residues do not contain substances
causing permanent damage or marking.
NOTE 1 The advice of manufacturers of these substances
should be sought to establish their suitability for use on stainless
steel.
NOTE 2 Austenitic stainless steel may corrode as a
consequence of being in contact or having its surface
contaminated with other materials. This may be as a result of the
contact material itself being corrosive or because a contact
material enables a corrosion phenomenon such as crevice or
galvanic corrosion to occur.
1
BS 7475:1991
4.3 Storage and handling
A dry, covered building shall be used for the storage
of all materials and shall be maintained in a clean
condition at all times.
Racking for materials shall be strongly built and
shall be lined in a secure manner with materials
that will not contaminate stainless steel, e.g. dry
wood, nylon or stainless steel. Unlined or painted
carbon steel racking shall not be used.
Lifting grabs shall be made from or lined with a
non-contaminating material.
4.4 Manufacturing and fabrication facilities
Manufacturing and fabrication facilities shall be
protected from inclement weather and draughts and
shall be dry.
Facilities for fabrication of stainless steels shall be
segregated from other works and kept free of all
possible contaminating materials such as lead, zinc,
copper/copper alloys or carbon steels, etc. (see 9.5.2
concerning the use of copper as a backing material).
Forming tools shall be cleaned thoroughly before
use to avoid cross contamination. All lubricants
used in the forming operations shall be removed
from the workpiece within 4 h of use.
Welding fixtures, such as clamps or manipulators
shall be either manufactured from or lined with
non-contaminating material.
5 Parent metal
In selecting the steel for the particular application,
care shall be taken to avoid grades that will suffer
from corrosion in the area of the weld under the
anticipated service conditions.
NOTE Appendix A gives guidance on metallurgical factors
affecting welds in austenitic stainless steels.
6 Welding process
The austenitic stainless steels can be joined using
the majority of welding processes but care shall be
taken with the high heat input processes to avoid
metallurgical problems (see Appendix A) and
distortion. The minimum necessary heat input shall
be used for all processes and materials, consistent
with obtaining satisfactory fusion.
7 Welding consumables
7.1 General
Consumables shall be selected having regard to the
application, i.e. joint design, welding position and
the properties required to meet service conditions.
Where there is an applicable British Standard, the
consumables selected shall comply and be coded in
accordance with that standard.
NOTE Appendix B gives a list of recommended consumables.
2 © BSI 02-1999
Consumables shall only be used in accordance with
manufacturers’ recommendations and shall only be
used for their specified application. Coated
electrodes shall not be stripped of their coating for
use as filler wires.
7.2 Shielding gases
For gas shielded arc welding processes, the torch
shielding, reverse side protection and trailing shield
shall be appropriate to the quality requirements
and the consumable used. Shielding gases
containing carbon dioxide shall only be used where
specifically recommended by the consumable
manufacturer.
NOTE 1 Guidance on the selection of shielding gases is given
in Table 1.
NOTE 2 For purging the reverse side of the weld during the
welding cycle, argon, helium or argon containing up to 5 %
hydrogen may be used subject to procedure approval.
NOTE 3 Carbon dioxide based shielding gases should not be
used with solid filler wires because there is a possibility of carbon
pick-up.
7.3 Storage and handling
All consumables shall be stored and handled with
care and in accordance with the manufacturer’s
recommendations; they shall be kept free from
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grease and other contaminents. Electrodes, filler
wires and rods and fluxes that show signs of damage
or deterioration shall not be used.
Consumables returned to stores shall be treated in
accordance with the manufacturer’s
recommendations before re-issue.
NOTE Consumables that have been exposed to poor storage
conditions or are suspected of being damp should, where
appropriate, be baked in accordance with the manufacturer’s
recommendations.
8 Equipment
8.1 Plant
Welding plant, instruments, cables and accessories
shall comply with the relevant Parts of BS 638. The
fabricator shall be responsible for ensuring that the
capacity of the welding plant and ancillary
equipment is adequate for the welding procedure to
be used and for maintaining all welding plant and
ancillary equipment in good working order.
NOTE The attention of the contractor is drawn to the advice on
safety precautions contained in Guidance Note PM 64 “Electrical
safety in arc welding” issued by the Health and Safety Executive
and published by HM Stationery Office.
8.2 Earthing
All electrical plant in connection with the welding
operation shall be earthed and shall use leads
appropriate to the application and as specified in
BS 638.
Earth clamps and all welding connections to the
workpiece shall be manufactured from or lined with
non-contaminating materials (see clause 4).
 BS 7475:1991

Table 1 — Guidance for shielding gas selection

Welding process Shielding gasa Further information

TIG Ar Continuous current Pulsed current

He Continuous current Pulsed current
Ar + 25 % to 80 % He Continuous current Pulsed current
Ar + 1 % to 5 % H Continuous current Pulsed current
Ar + 10 % to 25 % He + 1 % to 5 % H Continuous current Pulsed current
Plasma-arcb Ar Keyhole Melt-in
(high current) Ar + 5 % to 10 % H Keyhole Melt-in
Plasma-arcb Ar — Melt-in
(low current) He + 25 % Ar — Melt-in
Ar + 1 % to 5 % H — Melt-in
MAGc Ar + 1 % to 8 % O2 Dip Pulsed Spray
He + 10 % to 20 % Ar + O2 + CO2 Dip — —
Ar + 25 % to 50 % He + CO2 + O2 Dip Pulsed Spray
Ar + 25 % to 50 % He + 1 % to 5 % O2 Dip Pulsed Spray
Ar + 1 % to 5 % CO2 + O2 Dip Pulsed Spray
Ar + 25 % to 50 % He + CO2 + 1 % to 5 % H Dip Pulsed Spray
Flux-coredc Ar + 20 % to 25 % CO2 Globular Pulsed Spray
a
The composition of the gas mixture will be optimized by the gas supplier. The fabricator will therefore make his choice to suit the
application on hand.

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b In the case of plasma-arc welding involving both high and low current modes, the gas selections are intended for shielding, with
argon acting as the orifice gas in each case.
c
It is essential that shielding gases containing carbon dioxide only be used where specifically recommended by the consumable
manufacturer.

8.3 Tungsten electrodes 9 Butt weld details

Tungsten electrodes shall comply with
BS EN 26848. The size and type of tungsten
electrode selected and the tip preparation shall be
appropriate to the application. Contaminated
electrodes shall be replaced or restored to their
original condition.
NOTE The recommended electrode diameters and currents for
direct current welding are given in Table 2.
Table 2 — Recommended diameters and
welding currents for TIG electrodes
Electrode diameter Welding current
min.
9.1 General
The details of all butt joints, e.g. form of joint, angle
between fusion faces, and gap between parts, shall
be arranged to permit the use of a satisfactory
welding procedure (see clause 19). The combination
of weld detail and welding procedure shall be such
that the resultant joint will comply with the
requirements of the design. The ends of butt joints
in plate shall be welded so as to provide a weld of full
material section thickness.
NOTE This may be achieved by the use of extension pieces or
max. other means approved by the purchaser.

mm A A
Butt joints between parts of unequal cross section
shall be made and subsequently shaped such that a
1.2 8 25
severe stress concentration that could cause
1.6 20 70
premature failure is avoided. A taper between
2.4 40 120
adjacent items shall be no steeper than 1 in 4.
3.2 80 200
4.0 100 300

8.4 Instrumentation
Means shall be provided for confirming compliance
with the welding procedure. Electrode drying ovens
shall be provided with means of measuring the oven
temperature. All measuring instruments shall be
calibrated and have a certificate traceable to
national standards.

© BSI 02-1999 3
BS 7475:1991
9.2 Extension pieces
Where extension pieces are used these shall be
manufactured from a grade of austenitic stainless
steel compatible with that used for the fabrication
and shall have a thickness and edge preparation
identical to that used for the joint. Welding shall
start and finish within the preparation of the
extension pieces not less than 50 mm from the edge
of the joint for manual and semi-automatic
processes and not less than 100 mm from the edge of
the joint for automatic processes.
The method of removal of extension pieces shall be
specified by the manufacturer and shall be
performed by an appropriate method, which shall
not adversely affect the properties of the body of the
parent weldment, by the introduction of
metallurgical or physical defects that would be
detrimental to the performance of the fabrication.
9.3 Weld profile
9.3.1 In the as-welded condition, the weld surface
shall be proud of the surface of the parent metal.
The finished weld profile shall be as specified in the
application standard; where no application
standard exists, the weld profile shall be agreed
between the contracting parties [see 3.2 a)]. Where
dressing is required, the method of removal of the
excess weld metal shall be specified in the welding
procedure and shall not cause adverse metallurgical
change in the parent material that would be
detrimental to the performance of the fabrication.
9.3.2 Undercut and other surface irregularities
shall be minimized to optimize corrosion resistance
(see clause 24).
9.4 Full penetration butt welds
For joints welded from both sides, the weld, where
necessary, shall be excavated from the second side
to sound weld metal prior to depositing the root pass
on the second side. Finishing of the preparation
prior to welding shall be by machining or grinding.
Where the weld is to be made from one side only, the
first run shall be made using one of the following.
a) TIG/plasma welding or an alternative high
integrity welding process;
b) temporary or permanent backing strips;
c) reactive backing strips or pastes. The use of
reactive backing strips shall be by agreement
between the contracting parties [see 3.2 b)];
NOTE Care should be taken to ensure that these strips or
pastes are non-contaminating.
9.5 Backing material
9.5.1 Permanent backing shall consist of a
compatible grade of austenitic stainless steel.
4 © BSI 02-1999
9.5.2 When it is not appropriate to use part of the
structure as backing material, the material to be
used shall be agreed between the contracting
parties [see 3.2 c)].
When using copper as a temporary backing material
a groove shall be machined into the backing
material in the area immediately adjacent to the
fusion area.
NOTE 1 The dimensions of the groove should be appropriate to
the procedure.
Care shall be taken when welding as there is a risk
of copper pick-up in the weld metal. When using a
high heat input, copper backing shall be
water-cooled.
NOTE 2 The risk of copper pick-up can be reduced by nickel
plating of the copper backing material.
9.5.3 Backing material shall be free from grease,
moisture and oxide.
9.5.4 Where temporary or permanent backing
material is employed, the joint shall be arranged in
such a way as to ensure that complete fusion of the
parts to be joined is readily obtained.
9.6 Inert gas backing
Where required, the reverse side of single sided butt
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joints shall be protected from oxidation by the use of
inert gas backing. The gas shall be fed evenly to the
reverse side of the joint so as to exclude atmospheric
contamination.
The purging operation shall be commenced prior to
welding and shall be maintained for the period of
time that ensures protection of the joint against
oxidation. The flow rate shall be adjusted to cope
with the prevailing conditions.
NOTE 1 When inert gas backing is required, care should be
taken to ensure a supply of clean air to all areas where staff
might be affected.
NOTE 2 The time required for pre-purge is a function of the
maximum oxygen level permitted by the application
requirements, the size (volume) of the system being purged and
the purge gas flow rate.
NOTE 3 Where full penetration welds are required and
oxidation of the root bead is to be controlled, it may be necessary
to specify the maximum oxygen content in the backing gas.
Where such a requirement exists, appropriate means will be
required to monitor the gas composition. For pipework systems a
level of less than 1 % oxygen is often specified. To ensure that the
root bead is not discoloured, less than 0.5 % oxygen is desirable
with 50 mm diameter pipe, whereas for pipe or vessels
over 200 mm diameter oxygen levels approaching zero are
required.
NOTE 4 Where butt joints are to be made in pipe or hollow
sections, total system purging may be used. Alternatively, a
system may be used which isolates the backing gas to the area
requiring protection.
10 Fillet weld details
A fillet weld, as deposited, shall be not less than the
specified dimensions [see 3.1 a)] which shall be
clearly indicated as throat thickness.
 BS 7475:1991

Where the specified throat thickness of a fillet weld NOTE When no appropriate application standard exists, the
at the edge of a plate or section is such that the tolerances in Table 3 are recommended.
parent metal does not project beyond the weld, Table 3 — Recommended weld preparation
melting of the outer corner or corners, causing tolerances for butt joints
reduction in throat thickness (see Figure 1), shall Material Gas Tolerance
not be allowed. thickness
Root face Included angle
Fillet welds at the ends of open sections shall be Single V U and J
returned round the end of the section for a length of mm mm mm degree degree
not less than four times the throat thickness
(see Figure 1). up to 4 ± 0.5 ± 0.5  
  + 10
4 to 12 ± 1.0 ± 1.0  ±5  –0
11 Preparation of fusion faces over 12 ± 2.0 ± 1.0  
 
11.1 When mechanical methods of preparation are
11.4 Fusion faces and adjacent surfaces shall be free
to be used, the effect of work hardening shall be
from cracks, notches or other irregularities which
taken into account and precautions shall be taken to
would interfere with the deposition of the weld or be
ensure that there is no cracking at the edges of the
the cause of defects. Any repair to fusion faces shall
fusion faces.
be carried out in accordance with this standard.
In the cases where the cut edge is not a fusion face,
11.5 Fusion faces and the surrounding surfaces
the effect of the cutting shall not be detrimental to
shall be free from moisture, oil, paint or any other
the performance of the fabrication.
substance that might affect the quality of the weld
11.2 Methods for the preparation or cutting of the or impede the progress of welding. The fusion faces
material shall be by agreement between the and a 50 mm wide area adjacent to these shall be
contracting parties, [see 3.2 d)]. degreased prior to welding.

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11.3 The method of preparation of fusion faces, NOTE Liquid degreasers should be used with care and
angle of bevel, root radius and root face shall be such components should be allowed to dry completely before welding is
that the limits of accuracy required by the commenced. Consideration should be given to the risks of
phosgene formation when selecting liquid degreasers such as
appropriate application standard, if there is one, trichloroethylene or carbon tetrachloride.
can be achieved.

Figure 1 — Fillet welds applied to the edge of a part

© BSI 02-1999 5
BS 7475:1991

Table 4 — Alignment of butt joints for plates and sheets

Joint type Max. misalignment at joints

Material thickness, t

< 3 mm 3 mm to 10 mm > 10 mm
mm mm mm
Longitudinal seam 0.3 10 % t (max.) 10 % t (2 mm max.)
Circumferential seam 0.3 10 % t (max.) 10 % t + 1 mm (3 mm max.)
Single sided joints (long. or circ.) 0.3 10 % t (max.) 10 % t (1.5 mm max.)

12 Assembly for welding Table 5 — Alignment of butt joints

for pipes and tubes
Parts to be welded shall be assembled such that the
joints are easily accessible and visible to the Weld type Max. misalignment of joints at bore
operator. Pipe size
Where practical, clamps, jigs or manipulators shall < 150 mm diameter $ 150 mm
be used to ensure that the components are diameter
maintained in correct alignment during the welding
Autogenous 20 % t (0.5 mm —
operation and such that welding can be carried out
max.)
in the most suitable position. It is often beneficial to
Wire fill 1 mm max. 1.5 mm max
arrange for the clamping system to incorporate
copper or aluminium heat sinks so as to minimize
the risk of distortion, but care shall be taken to 14 Fit-up of parts joined by fillet welds
avoid contamination of the stainless steel with The edges and surfaces to be joined by fillet welds

material from the clamps or jigs.
Where clamps, jigs and manipulators are
impractical, tack welds shall be used to ensure
correct alignment.
NOTE Austenitic stainless steels are more susceptible to
distortion during welding than ordinary carbon steels. This
characteristic is attributable to the physical properties of the
austenitic stainless steels.
The coefficient of thermal expansion is approximately 50 % more
than that of carbon steel and the coefficient of thermal
conductivity is approximately 25 % of that of carbon steel. As a
result of the increased coefficient of thermal expansion,
austenitic stainless steels expand and contract significantly more
than carbon steel, during the heating and cooling of the welding
operation. This results in significantly higher expansion and
contraction stresses and consequently, a greater risk of
distortion. These effects are further exaggerated by the low
thermal conductivity of stainless steels, which leads to
concentration of the heat in the immediate vicinity of the weld,
and therefore to steeper temperature gradients.
13 Alignment of butt joints
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shall be in as close contact as possible since any gap
increases the risk of cracking; the gap shall not
exceed 20 % of the plate thickness or 3 mm
whichever is the lesser.
NOTE It is necessary to increase the leg length of the fillet weld
to compensate for a large gap.
15 Tack welds
Adequate tack welds shall be applied to retain the
components in alignment during the welding
process without cracking. The length of individual
tack welds and the frequency of such welds shall be
specified in the welding procedure. The tack welds
shall be applied in a balanced sequence to minimize
the risk of distortion and to maintain good fit-up.
NOTE Due to the risk of distortion, the number of tack welds
used should be greater than is normal for carbon steels, a spacing
of 10 t being recommended (where t equals the material
thickness).

The root edges or root faces of butt joints shall be
aligned to the limits given in Table 4 and Table 5, as
appropriate.
Where a tack weld is incorporated in a welded joint,
the shape of the tack shall be suitable for
incorporation into the finished weld, and shall be
free from cracks and other deposition faults. Tack
welds which crack shall be removed and rewelded
(see clause 25).
When depositing tack welds on closed butt joints,
care shall be taken to observe the requirements for
controlling oxidation of the penetration root bead
(see 9.6) and to avoid burning through.

6 © BSI 02-1999

16 Temporary attachments
16.1 Welds for temporary attachments shall be
made in accordance with this standard using
materials compatible with the main structure.
NOTE Temporary attachments should be as far from principal
joints as practicable and be kept to a minimum size to avoid
distortion and ensure ease of removal once the fabrication has
been completed.
16.2 When welded attachments used to facilitate
construction are required to be removed, this shall
be done carefully by cutting or grinding and the
surface of the material shall always be dressed
smooth by grinding followed by surface crack
detection using visual and liquid penetrant
inspection (in accordance with BS 6443) to confirm
absence of defects. Care shall be taken to ensure
that the thickness of the parent metal is not reduced
to less than that specified in the design. Temporary
attachments shall not be removed by hammering.
17 Stray arcing
Precautions shall be taken to avoid stray arcing on
the workpiece but, if it occurs, it shall be dressed
from the surface (see clause 25) and subjected to
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visual and liquid penetrant examination (in
accordance with BS 6443) to confirm its removal and
the absence of defects.
At the commencement of welding, the arc shall be
struck within the confines of the weld groove in the
case of butt joints or within the area of welding for
fillet welds.
18 Inter-run cleaning
Inter-run cleaning shall be carried out using a clean
stainless steel wire brush or iron-free alumina or
silicon carbide grinding medium complying with
BS 871 or an alternative technique agreed between
the contracting parties [see 3.2 e)].
Visible defects such as cracks, cavities and other
deposition faults shall be dressed out before the
deposition of further weld metal. Where chipping is
necessary, final cleaning shall be carried out using a
stainless steel wire brush.
Grinding wheels and wire brushes shall be
segregated and reserved for work on stainless
steels.
19 Details of welding procedure
Welding procedures shall be produced in accordance
with BS 4870-1.
Welders shall be provided with sufficient
information to enable the welding procedure to be
carried our satisfactorily.
© BSI 02-1999
BS 7475:1991
20 Approval and testing of welding
procedures
Unless otherwise agreed, written welding
procedures shall be provided by the contractor
(see clause 19) and the contractor shall be able to
satisfy the purchaser that he can make satisfactory
welds with the welding procedures to be used on the
contract [see 3.2 f)]. If so required by the purchaser,
the contractor shall carry out procedure tests in
accordance with BS 4870-1 [see 3.2 g)].
21 Approval and testing of welders
The contractor shall satisfy the purchaser that the
welders are suitable for the work upon which they
will be employed. For this purpose the welders shall
have satisfied the relevant requirements of
BS 4871-1.
22 Identification of welds
When specified by the purchaser, adequate means of
identification, either by an identification mark or
other record, shall be provided to enable each weld
to be traced to the welder(s) by whom it was made.
Care shall be taken in the use of marking materials
(see clause 4).
NOTE Attention is drawn to potential problems resulting from
hard stamping (for welder identification, radiographic
examination reference and other purposes). The designer should
give guidance as to the acceptability and/or location of such
marks.
23 Inspection and testing
23.1 The method and extent of inspection and
testing shall be in accordance with the application
standard where it exists.
23.2 If no application standard exists, the method
and extent of inspection shall be agreed between the
contracting parties [see 3.2 h)].
23.3 Welds which are to be inspected and approved
shall not be painted or otherwise obscured until they
have been accepted.
NOTE Guidance on the visual examination of welded joints is
given in BS 5289.
24 Quality of welds
24.1 Welded joints shall be free from defects that
would impair the service performance of the
structure (see also clause 25). Such acceptance
requirements, covering both surface and
sub-surface defects, shall be in accordance with the
application standard where it exists.
24.2 If no application standard exists, acceptance
requirements shall be agreed between the
contracting parties (see 3.2 i)].
7
BS 7475:1991

25 Correction of faulty welds 27 Weld finishing

Where welds do not comply with clause 24, the
defective portions shall be removed, the weld
repaired in accordance with this standard and then
reinspected in accordance with the application
standard. Unless otherwise agreed between the
contracting parties, no more than three attempts
shall be made at any specific repair [see 3.2 j)].
NOTE If undercutting is blended out by grinding, care should
be taken to ensure that the design thickness of the parent metal
is not reduced. If agreed by the purchaser, unacceptable
undercutting may be made good by the deposition of additional
weld metal; this should be carried out in accordance with this
standard.
The finish shall be appropriate to the end
application. Care shall be taken to avoid the use of
contaminating material (see clause 4). Where the
item is subjected to corrosive environments in
service, care shall be taken to avoid the creation of
crevices.
NOTE For optimum corrosion resistance it is recommended
that weldments are pickled and passivated.

26 Heat treatment
When heat treatment of welded fabrications is
required, this shall be carried out in accordance
with the application standard or, where no
application standard exists, the heat treatment
details shall be agreed between the contracting
parties [see 3.2 k)].
NOTE When specifying heat treatment of fabrications, due
consideration should be given to distortion, sensitization and
sigma formation of the final product (see Appendix A).

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8 © BSI 02-1999

Appendix A Metallurgical aspects
A.1 Sensitization or weld decay
One of the problems traditionally associated with
the welding of stainless steels is “sensitization”.
Before the introduction of the modern steel making
processes, stainless steels often contained carbon
contents up to (or even above) 0.08 %. As a result,
when austenitic stainless steels were held for any
appreciable time within the 500 °C to 900 °C
temperature range, or allowed to cool slowly
through this range, chromium carbide was found to
precipitate at the grain boundaries. A chromium
depleted zone formed about the carbides, which was
prone to attack if the steel was exposed
subsequently to certain corrosive media and the
steel was said to be sensitized. The attack was often
noted in the heat affected zone (HAZ) of weldments,
and the term “weld decay” was coined to describe
this form of intergranular corrosion.
The modern day steelmaking processes such as
argon/vacuum oxygen decarburization (AOD/VOD),
has enabled regular production of steels with
controlled carbon contents, typically 0.06 %
maximum for 304S and 316S grades respectively.
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Furthermore, low carbon or “L” grades are currently
available with less than 0.03 % which are far less
sensitive to carbide formation. Alternatively, the
carbon can be stabilized by addition of strong
carbide forming elements such as titanium or
niobium, as in the 321S and 347S grades. These
elements promote the formation of titanium or
niobium carbides in preference to chromium
carbides, thus preventing the creation of chromium
depleted zones. However, unlike molybdenum,
titanium and niobium do not increase the corrosion
resistance of the alloy per se, and so the use of
stabilized grades (321S or 347S grades) will offer no
advantage over plain 304S material in most
conditions.
A.2 Solidification cracking
Fully austenitic stainless steel weld metal is
susceptible to cracking during solidification. This
form of cracking, also known as “hot cracking”, is
due to the formation of low melting point regions at
the grain boundaries in the weld metal. During
subsequent contraction of the weld metal on cooling,
these regions are pulled apart to produce a tear. It
is well established that the selection of a
compositionally balanced consumable to produce a
deposit delta ferrite content in excess of about 2 %
reduces the risk of cracking.
© BSI 02-1999
BS 7475:1991
Solidification cracking is also known to depend on
welding conditions via their effect on the
solidification structure. A low heat input and low
interpass temperature (250 °C maximum) are
recommended. However, a fast travel speed
produces an elliptically shaped weld pool with a
coarse columnar structure encouraging centre line
segregation of impurity elements and cracking.
Thus, a balance needs to be struck between the
current and travel speed employed to obtain the
optimum welding conditions.
Recommendations for avoiding solidification
cracking are as follows:
a) reduce sulphur and phosphorus contents;
b) reduce restraint on the joint;
c) select a consumable to give a balance of
between 3 % and 8 % delta ferrite.
d) weld using low heat input;
e) reduce travel speed;
f) reduce interpass temperature.
A.3 Sigma phase
Sigma is a hard and brittle intermetallic phase
which can form in stainless steels after prolonged
exposure to the temperature range 550 °C
to 950 °C, reducing ductility, notch toughness and
corrosion resistance. The elements chromium,
molybdenum and silicon have been found to
promote the formation of sigma phase and,
therefore, steels containing high proportions of
these elements can be susceptible to sigma phase
embrittlement. Sigma is noted to form
preferentially at ferrite-austenite phase boundaries
and subsequently grow into the chromium,
molybdenum and silicon rich ferrite phase. For this
reason, stainless steel weld metals selected for
service within the sigma temperature range may
have limits placed on the maximum ferrite content.
This does not prevent sigma formation but inhibits
the formation of an interconnected network which
could form a brittle path for cracks.
The use of austenitic stainless steels for high
temperature service (above 600 °C) is common place
and there is some evidence that sigmatized material
can give satisfactory service, even though it is
known to have reduced creep rupture ductility.
However, problems may arise during shut-downs as
sigma has minimal low temperature toughness.
Elimination of sigma phase can only be ensured by
selection of a material with low chromium,
molybdenum and silicon contents or reheat treating
the steel at the solution annealing temperature
(1 150 °C for the 300 series austenitic stainless
steels) followed by rapid cooling.
9
BS 7475:1991

Appendix B Recommended consumables for gas shielded arc welding and

manual metal arc welding of austenitic stainless steels
Recommended consumables are given in Table 6.
Table 6 — Recommended consumables for gas shielded arc welding and manual metal arc
welding of austenitic stainless steels
Steel grade Steel type British Standard Wire consumable Manual metal arc electrode
complying with
BS 2901-2
301S21 Basic Cr-Ni BS 1449 BS 2926 19.9 L

BS 970  BS 2926 19.9 L

302S31 BS 1449/BS 1501  308S92 or 308S93 BS 2926 19.9 L

304S11 BS 1449  BS 2926 19.9 L
304S15 BS 1449  BS 2926 19.9 L

304S16 BS 1449/BS 1501  BS 2926 19.9 L
304S31

305S19 BS 1449 316S92 or 316S93 BS 2926 19.12.3 L

315S16 Mo containing and BS 1449  BS 2926 19.12.3 L

316S11 high alloy BS 1449/BS 1501  BS 2926 19.12.3 L

316S13 BS 1449/BS 1501  316S92 or 316S93 BS 2926 19.12.3 L

316S31 BS 1449/BS 1501  BS 2926 19.12.3 L

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
316S33 BS 1449/BS 1501 BS 2926 19.12.3 L

317S12 BS 1449 317S92 BS 2926 19.13.4 L

317S16 BS 1449 317S92 BS 2926 19.13.4 L

904S13 BS 1501 904S92 BS 2926 20.25.5 L

Cu Nb
320S31 Stabilized BS 1449/BS 1501  318S96 or 318S97 BS 2926 19.12.3 Nb

320S33 BS 1449  BS 2926 19.12.3 Nb
321S31 BS 1449/BS 1501  BS 2926 19.9 Nb
 47S96 or 47S97
347S31 BS 1449/BS 1501  BS 2926 19.9 Nb

309S16 Heat resisting BS 1501  BS 2926 23.12

 309S94
309S24 BS 1449  BS 2926 23.12

310S16 BS 1501  BS 2926 25.20


310S24 BS 1449  310S94 BS 2926 25.20

310S31 BS 970  BS 2926 25.20

NOTE 1 This table does not include all grades of weldable stainless steels and the advice of the consumable manufacturer should
be sought where other grades are to be welded or specific properties are sought.
NOTE 2 Particular care should be taken when welding free machining grades because of the associated risk of solidification
cracking.

10 © BSI 02-1999
 BS 7475:1991

Publication(s) referred to

BS 499, Welding terms and symbols.

BS 499-1, Glossary for welding, brazing and thermal cutting.
BS 638, Arc welding power sources, equipment and accessories.
BS 871, Specification for abrasive papers and cloths.
BS 970, Specification for wrought steels for mechanical and allied engineering purposes.
BS 1449, Steel plate, sheet and strip.
BS 1501, Steels for pressure purposes: plates.
BS 2901, Filler rods and wire for gas-shielded arc welding.
BS 2901-2, Specification for stainless steels.
BS 2926, Specification for chromium and chromium-nickel steel electrodes for manual metal-arc welding.
BS 4870, Specification for approval testing of welding procedures.
BS 4870-1, Fusion welding of steel.
BS 4871, Specification for approval testing of welders working to approved welding procedures.
BS 4871-1, Fusion welding of steel.
BS 5289, Code of practice. Visual inspection of fusion welded joints.
BS 6443, Method for penetrant flaw detection.
BS EN 26848, Specification for tungsten electrodes for inert gas shielded arc welding and for plasma cutting
and welding.
HSE Guidance Note PM 64 “Electrical safety in arc welding”1).

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1)
Available from HMSO, 49 High Holborn, London WC1 for personal callers, or by post from HMSO, PO Box 276, London
SW8 5DT.

© BSI 02-1999
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