On welding gray cast iron using SMAW and

GTAW process
Cite as: AIP Conference Proceedings 2088, 060002 (2019); https://doi.org/10.1063/1.5095350
Published Online: 29 March 2019

Asep Suharto, Doty Dewi Risanti, and Sekartedjo

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AIP Conference Proceedings 2088, 060002 (2019); https://doi.org/10.1063/1.5095350 2088, 060002

© 2019 Author(s).
 On Welding Gray Cast Iron Using SMAW and GTAW
Process

Asep Suharto1, a), Doty Dewi Risanti2, b), and Sekartedjo3, c)

1,2,3
Dept. of Engineering Physics, Institute of Technology Sepuluh Nopember Surabaya, Indonesia
a)
asep93st@yahoo.com
b)
d.d.risanti@gmail.com
c)
sekartedjo1@gmail.com

Abstract. This research work was carried to learn to repair technique to crack in gray cast iron material using welding
method. The welding process was done by shielded metal arc welding (SMAW) and gas tungsten arc welding (GTAW)
process with preheat and without preheating on the gray cast iron material. The type of welding filler metal was AWS
ENi-Cl (JIS Z3252 DFCNi) for shielded metal arc welding process (SMAW) and AWS A5.15 ERNi-Cl for gas tungsten
arc welding process (GTAW). The welding of the gray cast iron material was preheated at about 315-degree Celsius for
30 minutes and without preheating. The results of welding tested by visual test, liquid penetrant test, hardness test, optical
emission spectrometer (OES) test, macro photograph and microstructure test. The results indicate that heat treatment
produces a difference of hardness in HAZ area for SMAW and GTAW processes with preheat and without preheating.

INTRODUCTION

A serious breakdown occurred in compressor pneumatic housing of conveying system resulted in shut down of
pulverized coal transport. There was a failure and found crack 690 mm length on this compressor pneumatic
housing. This equipment is one of the critical categories in our operation. If it happens failure, it will impact
production loss. Corrective actions are taken to repair this equipment. The repair was done by SMAW process on
cracking area using filler metal ENiFeCl. The welding results were not satisfactory, there were still found cracks in
the weld area. This welding crack needs to be analyzed to find out the true cause. The research is needed to find out
the cause of the problem above.
This research work was carried to learn repairing technique to crack in gray cast iron using shielded metal arc
welding (SMAW) and gas tungsten arc welding (GTAW) process with preheat and without preheating. The types of
welding filler metal are ENi-Cl for shielded metal arc welding process and ERNi-Cl for gas tungsten arc welding
process.
This compressor pneumatic housing is made from gray cast iron material with chemical composition as shown in
Table 1 and it has value of tensile strength as shown in Table 2.
E El-Kashif and M A Morsy have conducted research on austempered ductile cast iron welding (ADI) using
SMAW process with AWS ENiFe-Cl electrode and buffering with E11018-G electrode [5]. Sachin B Sutar and Dr.
H Inamdar conducted a cast iron welding research using shielded metal arc welding and oxyacetylene welding
process with nickel-based welding wire and cast-iron rod (RCI) [6]. Prof. Dr. Asen Zlatarov conducted a study of
damaged cast iron cylinder head and recovery after welding [7]. Generousdi in the study stated to be need preheat
before cast iron welding to inhibit the formation of white iron [8]. Muhammad Khusnul Yaqin stated that using
nickel alloys in welding metal was very effective in reducing thermal stress, so that all test specimens were not

Advanced Industrial Technology in Engineering Physics

AIP Conf. Proc. 2088, 060002-1–060002-10; https://doi.org/10.1063/1.5095350
Published by AIP Publishing. 978-0-7354-1818-9/$30.00

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found welding crack or porosity even without preheat-postheat on gray cast iron FC 25 welding [9]. Sri Wahyu
Siswanto stated the influence of PWHT annealing temperature variation on the mechanical properties of gray cast
iron connected by SMAW process method [10]. Ravi Kumar and Gangoh Saharanpur conducted a review on
weldability of cast iron [11]. J H Devletian in his study stated that hardness in the weld metal region and HAZ
decreased significantly due to decrease weld cooling rate [12].
In this paper, the microstructure of gray cast iron welds is investigated in as weld condition and after applying
heat treatment of with preheat and without preheat using SMAW and GTAW process. The effect of preheating on
the hardness of the microstructural zones of the weld is also examined.
The purpose of the study reported here was to learn to repair technique to crack in gray cast iron material using
welding method and it is expected to obtain the best welding technique aimed at repairing damage to gray cast iron
material using SMAW and GTAW process.
TABLE 1. CHEMICAL COMPOSITION OF COMPRESSOR PNEUMATIC HOUSING AS GRAY CAST IRON
Element
Base Metal
%
C 5.135
Si 1.672
S 0.103
P 0.050
Mn 0.672
Ni 1.198
Cr 0.278
Mo 0.436
Cu 0.251
Sn 0.030
Fe Balance

TABLE 2. TENSILE STRENGTH OF A48 CLASS 40

ASTM A48 Specification
Property Cylinder Liner Diesel Engine Test
Class 40
Tensile Strength, Mpa 290  276

METHODOLOGY
Shielding metal arc welding (SMAW) using gray cast iron (ASTM A48 class 40) source material 12 mm in
thickness was carried out using a continuous welding current of between 70 and 140 A and straight polarity (DCEP),
a 3.2 mm electrode diameter that was previously heated at 100oC (to improve fluidity and hydrogen inclusion and
thereby prevent cracking). And TIG welding using same gray cast iron (A48 class class 40) material (dimension 100
mm x 300 mm x 12 mm in thickness) was carried out using a continuous welding current of between 70 and 121 A,
DCEN and an argon flow of 11 L/min.

Material

ASTM A48 class 40 gray cast iron in the as cast condition was used in this investigation. It’s taken from
Cylinder Liner Diesel Engine MBDG after in service. These test specimens were machined 300 mm x 100 mm x 12
mm thickness for subsequent welding. A 60-degree double V-groove was also machined into half of the test plates.
It has value of tensile strength as shown in Table 2. In order to duplicate the repair welding procedure used in
commercial practice, the surfaces to be welded were cleaned by using a hand operated grinder.

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 Welding

Single pass, bead on plate welds were deposited on flat test plates using the manual SMAW and GTAW process.
Multiple pass welds were deposited on the test plates containing the 60-degree double V-groove. The interpass
temperature was either specified preheating temperature or room temperature when no preheating was used.
All shielding manual arc welds made using a welding current as recommended current in TABLE 4 [13] and a
travel speed of approximately 52.1 mm/min with type of this filler metal was ENi-Cl.

Filler Metal

The composition and mechanical properties of the filler metal are very important consideration in the welding
cast iron. As each weld bead is made, filler metal and base metal are melted together. The change in composition of
the filler metal as a result of mixing with base metal is called dilution. Dilution should be minimized by welding
with the lowest heat input consistent [1].
Filler metals used to weld gray cast iron were 3.2 mm in diameter AWS ENi-Cl (CIN-1) SMAW process has
chemical composition of weld metal as shown in Table 3 and 2.5 mm AWS ERNi-Cl (Cascade 17T) GTAW process
as shown in Table 6.
All gas tungsten arc welds made using a welding current as recommended current in Table 5 and a travel speed of
approximately 53.4 mm/min with type of this filler metal was ERNi-Cl and shielded metal arc welds can be made
using a welding current as recommended current as shown in Table 4.
TABLE 3. TYPICAL CHEMICAL COMPOSITION OF CIN-1 [13]
C Si S P Mn Ni Fe

1.02 0.45 0.007 0.016 - balance 0.62

TABLE 4. SMAW RECOMMENDED CURRENT: (AC or DCEP or DCEN) [13]

Size Diamter 2.6 3.2 4
mm Length 300 350 350
Current Range 50 - 70 -
(Amp) 80 110 100 - 140

TABLE 5. GTAW RECOMMENDED CURRENT: (DCEN) [14]

Available Sizes and Amperages (AC/DC+)
(in) 3/32 1/8 5/32 3/16
(mm) 2.4 3.2 4 4.8
Amps. 50 - 70 70 - 100 100 - 130 130 - 160

Preheat

In many cases, preheating is not needed to produce an acceptable weld, but can be used to reduce the thermal
gradient and conductivity and to decrease the rate of cooling [3].
TABLE 6. TYPICAL CHEMICAL COMPOSITION CASCADE 17T (%) [14]
C Si S Cu Mn Ni Fe
0.037 0.44 0.24 0.02 0.24 balance O.02

The major concern with use of excessive preheat temperature are the resulting amount of unnecessary base metal
melted, a larger HAZ, and the formation of massive continuous carbides along the fusion line. Cast iron welding
requires careful selection of a preheat temperature if the weldment is expected to have the same mechanical
properties as the unaffected base metal. Continuous carbides are not a major concern,as gray cast iron is already
brittle because of its discontinuous flake graphite microstructure. [3]

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The formation of a hard and brittle heat affected zone (HAZ) can lead to cracking during cooling. Low heat input
with arc welding limits the width of the heat affected zone. Table 7 illustrates typical preheat temperatures necessary
to achieve a specific type of microstructure in the HAZ of cast iron [3].
TABLE 7. INFLUENCE OF PREHEAT ON HAZ CAST IRON [3]
Preheat Temperature, oC Resulting Microstructure
22 Martensite
100 Pearlite transformation occurs
A greater proportion of martensite and
200
carbides are replaced by pearlite
300 Almost all martesite is replaced by pearlite
400 All martensite is prevented

Because of the difficulty in welding gray cast iron and to avoid fracture due to stresses generated during
cooling, we welded the test pieces with preheat to 315oC and will be compared with specimens without preheat
before welding.

Control of Weld Cooling Rate

Slow cooling rates can suppress the formation of iron carbides and martensite microstructures in heat affected
zone (HAZ), which in turn reduce the propensity for weld cracking, by degreasing the hardness of the weld. Slow
weld cooling rates were obtained by preheating the workpiece. After welding, the specimens were slow cooled by
covering blanket sheet.

Peening

The principal effects of peening are relief of shrinkage stress, minimizing of distortion, and refinement of
microstructure. Peening is best performed at temperature that turn the metal a dull red. Peening performed below a
dull red heat cold works the metal and increases susceptibility to cracking. Peening should be performed utilizing a
½ or ¾ in diameters round nosed hammer. Repeated moderate blows should be used instead of a few heavy blows.
After peening, all slag should be removed by wire brushing before starting subsequent passes [3].
Peening done manually by chipping hammer.

RESULTS

The weldability of gray cast iron using ENi-Cl (SMAW) and ERNi-Cl (GTAW process) filler metal with preheat
and without preheat treatment were evaluated by chemical composition, tension test, hardness tests, microstructure
and metallographic analysis.

Chemical Composition Test Results

Chemical compositions of weld samples were examined using optical emission spectroscope. Table 8 shows the
result of chemical analysis by optical emission spectroscope and their comparison to base metal data.

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 TABLE 8. CHEMICAL ANALYSIS OF BASE METAL AND WELD METAL AT ROOT PASS
Element ID. No
Base
Metal #085 - GTAW Process #086 - GTAW Process #087 - SMAW Process #088 - SMAW Process
%
without Preheat with Preheat without Preheat with Preheat
C 5.135 1.293 2.133 0.633 0.761
Si 1.672 0.739 1.289 0.310 0.383
S 0.103 0.030 0.036 0.000 0.000
P 0.050 0.029 0.036 0.011 0.013
Mn 0.672 0.299 0.505 0.071 0.068
Ni 1.198 54.145 23.254 90.695 88.368
Cr 0.278 0.131 0.210 0.030 0.040
Mo 0.436 0.182 0.312 0.028 0.039
Cu 0.251 0.235 0.278 0.043 0.085
Sn 0.030 0.010 0.021 1.252 0.312
Fe Balance Balance Balance Balance Balance

Macrograph Results
Macrostructure of each weld specimen has been examined using stereo microscope to reveal the weld and
HAZ. Macrostructures are shown in Figure 1-2. Some porosities (white dots) is observed inside weld metals.
The quality, internal soundness and properties of the welded joints of gray cast iron was evaluated based on
several non-destructive tests. Besides assessing the quality of the weld joint, these tests also allowed us to evaluate
how neighboring of the weld area were affected during welding.

(a) (b)
FIGURE. 1. Macrostructure of weld joint after surfacing by welding GTAW of gray cast iron
(a) specimen #085 – without preheating, (b) specimen #086 – with preheating temperature 315oC)

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 (a) (b)
FIGURE. 2. Macrostructure of weld joint after surfacing by welding SMAW of gray cast iron
(a) specimen #087 – without preheat, (b) specimen #088 – with preheating temperature 315oC)

Tensile and Hardness Test Results

Tensile test results are importance, they give a direct indication of mechanical capabilities of welded joint. They
also allow for a quick assessment regarding the viability of a given heat treatment methodology, as the closer the
results are to those of base material (BM).
The HV micro hardness was measured with 200 g loads for 10 s with a diamond point at 136o. Measurements were
taken at base metal, heat affected zone (HAZ), and weld metal (a total of fithteen measurements) using Vickers
Microhardness tester. The mechanical properties are shown in Table 9 and Table 10. The tensile tests to determine
the mechanical properties were carried out in accordance with ASTM A 370 standard for tensile tests at room
temperature.
TABLE 9. MECHANICAL PROPERTIES OF THE GRAY CAST IRON WELDS – GTAW PROCESS
Tensile Strength, Hv Hv Hv Element
Heat Treatment Process ID no. Electrode Fracture
Mpa Base Metal HAZ Weld Metal C
270 765 220 42.30%
154 670 220
Without Pre-
AWS A5.15 ENi- 220 670 231
heating and slow GTAW #085 93 HAZ
CI 700 231
cooling
700 191
592 210
256 548 210
Without Pre- 256 569 210
heating AWS A5.15 ENi- 256 490 270
GTAW #086 160 HAZ 27.10%
temperature 315 C CI 548 231
and slow cooling 700 231
616 231

TABLE 10. MECHANICAL PROPERTIES OF THE GRAY CAST IRON WELDS – SMAW PROCESS
Tensile Strength, Hv Hv Hv Element
Heat Treatment Process ID no. Electrode Fracture
Mpa Base Metal HAZ Weld Metal C
302 472 243
243 385 231
Without Pre-
AWS A5.15 ENi- 320 526 256
heating and slow GTAW #087 72 HAZ 38.73%
CI 507 243
cooling
526 110
507 210
256 502 231
Without Pre- 243 490 231
heating AWS A5.15 ENi- 210 455 210
GTAW #088 74 HAZ 35.5 1%
temperature 315 C CI 381 210
and slow cooling 643 210
643 220

Microstructure Test Results

The base metal, HAZ and the weld regions were microscopically viewed and examined in order to see the
microstructural evaluation along the welded with preheat and without preheat gray cast iron.

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 FIGURE. 3. Base Material Microstructure of Gray Casy Iron Showing Flake Graphites (Low Magnification)

(a) (b) (c)

FIGURE. 4. Microstructure of specimen #85 welded by GTAW process without preheat (a) base metal, (b) HAZ and (c)
weld metal (Etch; 5% HNO3)

(a) (b) (c)

FIGURE. 5. Microstructure of specimen #86 welded by GTAW process with preheat (a) base metal, (b) HAZ and (c) weld
metal (Etch; 5% HNO3)

(a) (b) (c)

FIGURE. 6. Microstructure of specimen #87 welded by SMAW process without preheat (a) base metal, (b) HAZ and (c)
weld metal (Etch; 5% HNO3)

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 (a) (b) (c)
FIGURE. 7. Microstructure of specimen #88 welded by SMAW process with preheat (a) base metal, (b) HAZ and (c)
weld metal (Etch; 5% HNO3)

ANALYSIS OF RESULTS AND DISCUSSION

Analysis of Chemical Composition

A48 class 40 material (taken from Cylinder Liner Diesel Engine MBDG) contains the high amount of carbon and
silicon as shown in Table 8 which indicated that cylinder liner material is probably gray cast iron, however, further
verification by microstructural analysis and the tensile test will be required.
Figure 3 shows the optical micrograph of cylinder liner material as a base material. It is clear that liner material
is gray cast iron as shown by the presence of flake graphite in the microstructure. This corresponds to the findings
from the literature review [4].
Weld deposit specimens welded by SMAW process have higher nickel content than weld deposit specimens
welded by GTAW process because ENiCl electrode is pure nickel core which has high nickel content.

Analysis of Macrograph

Macrograph testing was carried out to see the weld metal, HAZ and base metal parts of the weld specimen
visually. This macrograph testing aims to see weld cracks and porosity. As shown in Fig. 1-2, there are not found
weld cracks and but found porosities.
Gray cast iron welds are susceptible to the formation of porosity. Preheat temperature (315oC) was not enough to
reduce gas entrapment in gray cast iron.
In addition, as shown in Table 8 that gray cast iron as base metal contents high carbon. This high carbon can be
oxidized to become a CO gas, which tends to cause blowholes (porosities) in the weld metal as shown in
Macrograph result.
All specimens are free of weld cracks even though the specimen without preheating.

Analysis of Tensile and Hardness

The result of hardness can be seen in Table 9, in GTAW process which specimen tested with preheat (315oC)
and without preheat, all HAZ regions have higher hardness than weld metal and base metal region, because the HAZ
region is a metal part which is affected directly by heating (welding) process, so that the atoms are distorted causing
residual stress. This residual stress increases the value of hardness in the HAZ regions.
In GTAW process which specimen with preheating (315oC), hardness in HAZ regions have lower hardness than
specimen tested without preheat as shown in Table 9, these due to preheating can decrease residual stress and
hardness in HAZ area.
As well as SMAW process which specimen with preheat (315oC) and without preheat, HAZ regions have higher
hardness than weld metal and base metal region, because the HAZ region is a metal part which is affected directly
by heating process, so that the atoms are distorted causing residual stress. This residual stress increases the value of
hardness in the HAZ region.
As shown in Table 2, this material taken from cylinder liner engine has tensile strength 290 MPa including as
gray cast iron specification.

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 Table 9 and 10 shows that preheating can increase tensile strength both gray cast iron welded by GTAW or
SMAW process. Specimens welded by GTAW process both with preheat and without preheat have higher tensile
strength than specimens welded by SMAW process.
All specimens welded by GTAW and SMAW process with preheat and or without preheat are fractured in HAZ
area (brittle fractured). Gray cast irons are comparatively week and brittle in tension due to its microstructure, the
graphite flakes have tips which serve as points of stress concentration.

Analysis of Microstructure

Based on the results of microstructure images on the HAZ specimen welded by GTAW process, it can be seen on
the specimen without preheat graphite growth occurs larger than base metal and spreads in large numbers. The
perlite lamellar matrix that is formed very smooth and tight. Large, scattered graphite and perlite matrix smoothly it
causes high hardness on HAZ region. Preheating influences graphite growth and matrix able to decrease hardness on
HAZ region as shown in Table 9. Fig. 3 shows widmanstatten structure on weld specimen without preheating. The
phenomenon of widmanstatten structure is caused the material to experience rapid cooling.
Fig. 6 and 7 show a typical microstructure of the weld joint welded by SMAW process with a 99.02 % Ni
electrode without preheating. From the Fig. 6 and 7 they were found that the HAZ region is visually darker due to
less amount of ferritic matrix structure resulting from the dissolution of ferrite in nickel. As shown in Table X the
hardness of HAZ was found to be 526 HV (164 % higher than 320 HV base metal) and was lesser than the hardness
value of HAZ without preheating welded by GTAW process.
The result of microstructure image Fig. 6 and 7 on the HAZ region welded by SMAW, it can be seen on the
microstructure image with preheat graphite growth occurs more than graphite growth on HAZ region without
preheat. As shown in Table X the hardness of HAZ was found to be 643 HV (251% higher than HV base metal) and
was more than the hardness value of HAZ without preheating welded by SMAW process.

CONCLUSION AND DISCUSSION

Conclusion

Gray cast iron plates were welded using two different welding processes at two different heat treatment
conditions. The following conclusions were arrived at:
1. In gray cast iron welded by GTAW process with preheat, preheating can reduce hardness in the HAZ area
and increase the tensile strength of the HAZ area.
2. The temperature of pre-heat 315oC carried out on the gray cast iron welded by GTAW process was not
enough to replace all martensite phases to pearlite phases.
3. The HAZ area is a region that has the higher hardness compared base material and weld metal.
4. All specimens tested fractured in the HAZ area (brittle fractured).
5. In gray cast iron welded by SMAW process with preheat, preheating can increase the tensile strength of the
HAZ area.
6. If tensile strength is not considered, gray cast iron can be welded by SMAW and GTAW welding process
with preheating or without preheating, both SMAW or GTAW process using high nickel filler metal.
7. With the test results above, the repairing/welding of gray cast iron in our plant facility is more effective
using the SMAW process without preheat if the tensile strength is not considered where the equipment is
more flexible, it does not use additional shielding gas, welding wire is cheaper than the GTAW process.

Recommendation
For the further research, there is a recommendation to be needed attention, the research can be carried out by
increasing the temperature of preheating equal or greater than 400oC, it is expected to replace all martensite phases
into pearlite phase, it can reduce the hardness in the critical HAZ area and it increases the tensile strength in HAZ
area.

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